Island Enterprises Island Enterprises TABLE OF CONTENTS
SECTION PAGE
I. INTRODUCTION...... ~...... 1-1
A. GENERAL...... ,...... 1-1 B. SCOPE OF MANUAL...... 1-1 C. DESCRIPTION...... :...... 1-1 D. SPECIFICATIONS OUTLINE...... 1-4
11. HANDLING AND SERV1CING...... 2-1
A. GENERAL...... 2-1 B. ACCESS PROVISIONS...... 2-1 C. GROUND HANDLING...... 2-1 1. Jocking...... 2-1 2. Mooring 2-1 3. Towing 2-1 4. Leveling 2;3 5. Weight 8 balance 2-3 DI SERVICING...... 2-4 1~ Fuel system...... 2-4 2. Engine lubricotion...... 2-7 3. Brake sysrem...... 2-7 4. Bortery...... 2-7 5. Induction sysrem...... 2-7 6. Vacuum step system...... 2-7 E. LtlBRICATION...... ~...... 2-7 F. EXTERIOR AND INTERIOR CARE...... 2-9
111. POWER PLANT...... 3-1
A, GENE RAL...... 3-1 B. TROUBLE SHOOTING...... ~...... 3-1 C. )NDUCT1ON AIR FILTER CARE...... 3-1 D. ENGINE R EMOVAL...... 3-1 E. PROPELLER REMOVAL...,...... 3-2 F. INSTALLATION OF ENGINE...... 3-2 G. INSTALLATION OF PR·OPELLER...... 3-2 H. ENGINE CONTROL AD~USTMENTS...... 3-2
IV, STRUCTUR E...... ~.. 4-1
A. 4-1 B. REMOVAL OF WING...... 4-1 1. Removal of wing...... 4-1 2. Installation of wing...... ,...... 4-2
V. LANDING GEAR AND BRAKE SYSTEM 5-1
A. GENE RAL...... 5-1 B. REMOVAL OF LANDING GEARS'...... 5-1 i. Main gear...... 5-1 2. Nose geor...... 5-1 C. REMOVAL AND DISASSEMBLY OF SHOCK D iSCS...... ·...... ~...... 5-3 D. REASSEMBLY AND INSTALLATION OF LANDING GEAR...... 5-3 1, Main geor...... 5-3 2. Nose geor...... ~...... 5-3 E. BRAKE AND WHEEL MAINTENANCE...... 5-6 1. Blake lining inspection and ~eplacement...... 5-6 2. Brake bleeding...... 5-15 3. Wheel assembly inspection...... 5-15
REVISED NOVEMBER 1966 iii
Island Enterprises SECTION PAGE F. LANDING GEAR RIGGING PROCEDURE 5-15 1. Rigging instructions 5-15 2. Inspection of preload 5-16 3. Adiustment of prelood 5-17 G. INSPECT1ON OF LANDING GEAR SHOCK ABSORBER- 5-20 1. Rubberdiscs 5-20 2. Collars and bolts 5-20 3. Nose gear snubber 5-20 H. ELECTRIC GEAR SYSTEM (OPTIONAL) 5-23 1. Operation 5-23 2. Manual operation of electric gear 5-23 3. Gear inspection 5-23 4. Electric gear rigging procedure 5-24
VI. CONTROL SYSTEMS 6-1
A. GENERAL 6-1 B. REMOVAL AND INSTALLATION 6-1 1. Ailerons 6-1 2. Rudder 6-1 3. Elevators 6-1 4. Flaps 6-1 C. CONTROL SURFACE BALANCE DATA 6-2 D. RIGGINGAND ADJUSTMENT 6-2 i. Aileron rigging and adiustment 6-2 2. Trim rigging and odiustment 6-3 3. Flap rigging and adiustment 6-3 4. Rudder rigging and adiustment 6-3 5. Elevator rigging and adiustment 6-4 6. Trailing edgetrimming 6-4 7. Hydraulic flap bleeding 6-4 E. CONTROL TRAVEL AND RIGGING SPECIFICATIONS 6-7 F. POSITIVE CONTROL SYSTEM. 6-17 1. Introduction 6-17 2. System description 6-17 3 test Ground procedure .,....,.._ 6-18 Roll,/yaw system 6-21 5. instructions and test.. Operating flight ...... _., 6-22 6. 6-22 Emergency procedures ...,.....,_ 7 Ma r.tenance 6-23 8. ':ouble shooting 6-23 9 T·~sSie shooting tests 6-25
Vli. FUELSYSTEM 7-1
A. GENERAL 7-1 B. TROUBLE SHOOTING 7-1 C. REMOVAL AND INSTALLATION OF FUEL PUMPS 7-2 Electric fuel pump removal 7-2 2. Electric fuel pumpremoval 7-2 3. Installation of electric fuel pump. 7-2 4. Engine-driven fuel pump 7-2 D. REMOVAL AND INSTALLATlaN OF FUEL SELECTOR VALVE. 7-2 E. FIELD REPAIR OF FUEL TANi;S 7-3 i. General 7-3 2. Approved materials 7-3 3. Handling and mixing sealant 7-4 4. Sealantappjication instructions 7-5 5. Description of leaks 7-8 6. Leak detection 7-8 7. Leakrepairprocedure. 7-11
Island Enterprises Vllt. ELECTRICAL 8-1
A. GENER4L...... ~...... ,..... 8-1 B. TROUBLE 8-1 7. Electrical switches and circuit breakers 8-1 2. Batterr...... ·...... ;...... ,...... 8-1 3. Battery charging system...... ,...... 8-2 4. Voltage regula·tor~.-.,...... ,...... 8-2
IX. INSTRUMENTS 9-1
A. GENERAL...... 9-1 B. TROUBLE SHOOTING...... :...... ~...... 9-1
X. INSP ECTI 10-1
A. 10-1 8. PREFLIGHT INSPECTIONS...... 10-1 C. 25-HOUR INSP ECTIONS...... ~...... 10-2 D. 50-HOUR INSPECT1ONS...... 10-3 E. 100-HOUR .INSPECTIONS...... ;...... ~...... 10-4 F. OVER-LIMITS INSPECTIONS...... ~...... 10-4 G. POST INSPECTION 10-4 H. ELECTRIC GEAR INSPECTION (OPTIONAL INSTALLAT.ION)...... 10-5
X1. PAINTING AND PREVENTION OF CORROSION...... ~...... 11-1
A. GENERAL...... ~...... ·...... 17-1 B. PAINTING...... 11-1 1. Materia Is...... ,.., 1:1-1 2. Procedures.,...... ,...... 17-2 C. CORROSION DETECTION PREVENTION...... 11-4 1. Types of cot·rosion...... ,...... ,...... 11-4 2. Hints on preventing corros ion...... ,...... 11-4 3. Zinc chromare...... ,...... 11-4
APPENDIX
Tool and equipment list Four-to-six digit cross-reference index Mooney technical publications list
Island Enterprises INDEX OF ILLUSTRATIONS
FIGURE TITLE PAGE
1-7 M20C (1 962-1964) THR E E V1 EW 1-7 I-1A M20D (1963-1964) THREE VIEW--..······...... 1-8 1-1B M20E (f 964-1965) THREE VIEW '1-9 7-7C M20C (1965) THREE VIEW 1-10 l-1D M20D (1965') THREE VIEW 1-1'1 7-7E M20C (7 966 8 ON) TH RE E VI EW...... 1-12 ~r-7 F M20D (1966 8 ON) TH R E E V I EW.....~..... 1-13 M20E (1966 8 ON) THREE XIEW...... 7-14 7-1H M20F (7967 8 ON) THREE VIEW...... 1-15 2-1 2-2 2-2 LEVELING...... ~...... 2-2 23 PLUMBING...... ~...... 2-3 2-3A WEIGHT 8 BALANCE COMPUTATION (M20C,D,&E)...... 2-3A 2-38 WEIGHT 8 BALANCE COMPUTATION (M20F).....~...... 238 2-4 FUEL SELECTOR VALVE ASSEMBLY...... 2-5 2-5 Oil DIPSTICK ACCESS-...... :...... ~2-5 26 Oil QUICK DRAIN 2-6 2-7 011 SCREEN STRAINER LOCATIONS...... 2-6 2-8 VACUUM STEP SYSTEM INSTALLATION...... ,...... 2-8 2-9 LUBRICATION DIAGRAM 2-11 3-1 COWL FLAP OPEN~NG...... ,...... 3-3 4-1 W ING AND FCIS E LAGE MATING D IAGRAM 4-3 4-2 WING SKIN CHART.. 4-4 43 TA 1L S KIN CHA RTS 4-5 4-4 FUSELAGE SKIN CHARTS 4-6 5-7 GEAR R ETRACTION SPRING REMOVA L...... 5-2 5-2 NOSE GEAR SHOCK 31SC REPLACEMENT TOOL APPLICATION...... 5-4 5-3 MAIN GEAR SHOCK DISC REPLACEMENT TOOL APPLICATION 5-5 5-4 NOSE GEAR DOOR RIGGING DIAGRAM;...... 5-7 3-5 BRAKE CYLINDER ASSEMBLY 5-9 5-6 WHE EL ASSEMBLY CHART 5-1 0 5-7 HYD RAULIC BRAKE MASTER CYLIND ER ASS EMBLY...... ~...... 5-1 1 5-8 PARKING BRAKE VALVE ASSEMBLY 5-12 5-9 PARKING BRAKE VALVE ASSEMBLY (ALTERNATE) 5-13 5-10 GEAR RIGGING DIAGRAM 5-14 5-11 TORQUE WRENCH APPLICATION DIAGRAM 5-19 5-12 LAND ING GEAR SHOCK D ISCS INSP ECTION D IAGRAM...... 5-21 5-13 LANDING GEAR SHOCK D~ISCS INSPECTION DIAGRAM (1966) M20C 8 E...... 5-22 5-14 ELECTRIC GEAR RIGGING COMPONENT 5-24 5-15 SAFETY SWITCH AND EMERGENCY GEAR CRANK INSTALLATION·..·.··--·-- 5-25 5-76 ELECTRIC GEAR RETRACTION SYSTEM INSTALLATION...... 5-26 5-17 ELECTRIC GEAR \YIR ING SCH EMATIC (1 965).-.-...... -...... ~...... 5-27 5-7 8 ELECTRIC GEAR WIRING SCH EMATIC (1 966)...... ,...... 5-28 5-79 ELECTRIC GEAR WIRING SCHEMATIC (1 967)...... :...... 5-29 6-1 CONTROL SURFACE BALANCING 6-2 6-2 TRAILING EDGE TRIMMING DIAGRAMS-.----..---··---·--.·-·--···---····-----··-·--··-·-···-----··-· 6-5 63 APPLICATION OF TRAILING EDGE TRIMMING VICE-GRIP PLIARS 6-6 6-4 CONTROL TRAVEL ~iGS...... ,...... 6-8 6-5 RUDDER CONTROL SYSTEM INSTALLATION 6-9 6-6 ELEVATOR CONTROL SYSTEM INSTALLATION 6-10 6-7 AI1EROA CONTROL SYSTEM INSTALLATION-...... 6-11 6-8 TRIM CONTROL SYSTEM INSTALLATIOU...... 6-12 6-9 TRIM CONTROL ACTUATOR ASSEMBLY 6-13 6-10 FLAP CONTROL SYSTEM INSTALLATION 6-14 6-11 FLAP PUMP AND VALVE ASSEMBLY...... ,...... 6-15 0-12 FLAP CYLINDER ASSEMBLY 6-16 6-13 CUTOFF VALVE OPERATING CHECK DIAGRAM.,...... 6-19
vi REYISED NOYEMBER 1966
Island Enterprises FIGURE TITLE PAGE
6-14 PILOT VALVE OPERATING CHECK DIAGRAM...... 6-20 6-15 PRIMARY VACUUM READING DIAGRAM (1965 1966 MODELS)...... 6-20 6-15A GYRO ROTOR SPEED ADJUSTMENT (1965 1966 MODELS)...... 6-21 6-16 RATE GYRO VALVE CENTERING DIAGRAM (1965 1966 MODELS) 6-22 6-17 POSITIVE CONTROL SYSTEM INSTALLATION (8 SHEETS)...... 6-27 7-'1 TANK SEALANT APPLICATION DIAGRAM...... -...... · 7-6 7-2 FUEL LEAK CLASSIFICATION DIAGRAM...... · 7-9 7-3 TANK AREAS WHERE FUEL LEAKS CONSTITUTE A FLIGHT HAZARD...... 7-10 7-4 FUEL TANK -LEAK DETECTION DIAGRAM 7-12 8-1 VOLTAGE R EGO L;4TO R S ETT1N G CHART.. 8-4 8-2 ELECTRICAL SYSTEM DIAGRAM (1962 M20Cr...... 8-11 8-3 ELECTRICAL SYSTEM DIAGRAM (1963 M20C)...... 1...... 8-12 8-4 ELECTRICAL SYSTEM DIAGRAM (1963 M20b) 8-'13 8-5 ELECTRICAL SYSTEM DIAGRAM (1964 8-14 8-6 ELECTRICAL DIAGRAM 11964 M20C) 8-15- 8-7 ELECTRICAL SYSTEM DIAGRAM 11964 8--16 8-8 ELECTRICAL SYSTEM DIAGRAM (1964 M20E)....~...... 8-17 8-3 ELECTRICAL SYSTEM DIAGRAM (1954 M20E)...... :...... 8-1e 8-10 ELECTRICAL SYSTEM DIAGRAM 11965 M20C) 8-19 8-11 ELECTRICAL SYSTEM DIAGRAM 11965 M20D) 8-20 8-12 ELECTRICAL SYSTEM DIAGRAM i1965 hn~CE) 8-21 8-13 ELECTRICAL SYSTEM DIAGRAM i1966 M20C) 8-22 8-14 ELECTRICAL SYSTEM DIAGRAM 11966 ON M200)...... 8-23 8-15 ELECTRICAL SYSTEM DIAGRAM (1966 M20E)...... 8-24 8-16 ELECTRICAL SYSTEM DIAGRAM (1967 M20C&E)...... 8-24A 8-17 ELECTRICAL SYSTEM DIAGRAM (1967 M20F)...... ~...... 8-30 10-i ACCESS PANEL REMOVAL DIAGRAM ('100-HOUR INSPECTrON)...... 10-7 10-2 POWER BOOST DOOR SEAL INSPECTION D IAGRAM...... 10-8
LIST OF TABLES
TABLE TITLE PAGE
1 ENGINE AND PROPELLER SPECI FICATIONS...... i-6 2 POSITIVE CONTROL SYSTEM TROUBLE SHOOTING 6-23 3 FUEL SYSTEM TROUBLE SHOOT;NG..... 7-1 3 TANK SEALANT APPLICATION LIFE CURING TIME...... 7-4 5 HYDROMETER READING VS. BATTERY CHARGE PERCENT 83 6 ELECTRICAL SYSTEM TROU BLE SHOOT ING 8-5 7 INSTRUMENT TROUBLE SHOOTING 9-2 8 EXTERIOR PAINT CHART-·------·-.--...... 11-3
REVISED NOVEMBER 19~6 vii
Island Enterprises MOONEY AIRCRAFT
TWELVE-MONTlH c~ WARRANTY
Company warrants each new airplane manufactured by it to be free from defects in material and work- manshiD under normal use and service, Drovidsd, however. that this warranty is limited to making good at Company's factory any oan or ~ans hereoF which shall, within 12 months from date of original Air- worthiness certificate, be returnkr to Com_oany with transportation charges prepaid, and which upon Company's examination shall disclose to Company's satisfaction to have been thus defective; this warranty being expressly in lieu of an other warranties or implied and all other obligations or liabilitia~ on the part of the Com_Dany, and Com~any neither assumes nor authorizes any other person to assume for it any other liability in connection with the sale of its airplanes. Ihis warranty shall no: apply to any air- plane which shall have been repaired or altered outside of Com_oany's ~ctory which in the judgment of Company affects the airplane's ~ability or reliability, nor which in the ooinion of Company has been sub- Ject to misuse, negligen~e or accident. Zcpipment and accessories not manufactured by seller are guzr- anteed only to the extent of the original manufacturer's
YIZ1 REYISED NOVEMBER 1966
Island Enterprises SECTION
INTRODUCTION
Island Enterprises SEC~ION I 1NTRODUCTION
A~
This manual contains service and maintenance information pertaining to all M20 series aircraft cr~ -r listed on the title page.. All affected aircraftare identified by year of manufacture, model designation, and serial number ~ouning. When service and maintenance instructions in the body of the manual refer to a sDecific year and model, applicability of dtm information to an individual aircraft may be determined dy referring to the title page serial-number listing.
If it becomes necessary to consult the factory concerning a specific maimenance problem, contact the Customer Service Department, Mooney Aircraft, inc., Kerrville, Texas, 78028. Telephone, Area Code 5~2, 257-4043.. When ~eryin,o the factory or forwarding information, the model designation, serial number, and re~istration number of the aircraft concerned shouldbefurnished. Total in- service rime for the item in c~estion should also be furnished,
Spare pans are available throu~ the ~Ylooney distributor in your area. Consult the Mooney Parts Catalog for the latest pan numbers and the correct ordering procedure. Mooney manufactured parts were changed from a four digit to a six digit numbering system in Enarch of 1962. New pans may be ordered by either their four or six digit numbers. A six-to-four digit cross reference index is included in the aDpendix.
9. SCOPE
For ready reference, this manual has been divided into eleven sections, each dealing with a major system or group of comionents. Sections Ii and X comprisetheservice porrian oithehzndbook; the remaining sections are devoted to maintenance. Service instructions include ground handling, servicing, and periodic inspection. Maintenulce instructions include trouble shooting, corrective maintenance and functional testing, and removal and installation of assemblies andcomoonents. Only qualified personnel should _oerform inspections and maintenance procedures described in this manual.
Basic information in this manual is limited to service anh maintenance procedures peculiar to the aircraft concPJ~ed; no attempt is made to cover standard shop procedures. Refer to the applicable Owner's Manual for oDerating details. For niore complete maintenance infonnation concerning en- ~nes, oro_Dellers, and other vendor items, the manufacturer's handbooks should be consulted. An annual service information subscription or a complete back-issue file of Mooney service information is available from your local Mooneydistributor.
C. IIESCilIPTIO~
Mooney X1120 series aircraft are desi~ed and manufactured as high performance, low maintenance, versatile aircraft for the oersonal and business aviation field.
The M20 series aircraft discussed in this manu~al are four-place all-metal low-wing aircraft. All models are powered by Lycoming engines. RefertoTzble 1 for propeller and governor specifications.
Conventional rudder Dodals and control wheels are provided. Entrance to the cabin is made through the cabin door locste~ on the right side of the airplane. The from seats fold forward to allow passen- ger enrry to the rearsezts. Theba~,oagetompanment is located aft of the rear seat and has an access door on the right side of the aircraft. During flight, the baggage compamment is accessible from the rear seat.
1-1
Island Enterprises 1. ENCINEII
a. An M20C aircraft are powered by a Lyc~ming_O-360-A1D engine equip_Ded with a constam-speed propeller,
b, M20D aircraft (1963) are e~ipped with a Lycoming 0-360-AlD engine~having a governor control
c. M20D aircraft (1964 thru 1966) are ec~ip_oed with a Lycoming 0-360-A2D enginehaving a fixed- The 0-360-,41D be installed as oDtiondl ~c. pitch propeller. engine may I-~0 d. Lycoming 0-360-A1D and 0-360-A2D engines are both rated hp at 270~rpm.
e. All M20E aircraft are powered by a Lycoming 10-360-.4W engine rated 200 hp at 27(30 rpm.
f. An M20E aircraft are orovided with a ram induction air source. Filtered air is used during takeoff, ~andLng, and under dusty conditions. Air source selection is made by man- ual control, An emergency fn_c~uction air source is provided; in ti,e event of filter icing, a spring- loaded valve, located behind the filter inside the engine compartment, will open automatically to maintain air flow;o the engine. To Drevent ice iorma~fon in the induction system, the power boost control must be set for ffltlred air ii icing conditions are present,
2. PROPELLER
Those models with constant-s_oeed propellers have low pitch setting capabilities for maximum take- on' power. Propeller pitch is regulated by an engine-mounted governor that insures maximum power efficiency at cruising speeds, Engine oil pressure actuates the pitch changing mechanism.
3. WZNG
All M20 series aircraft have laminar-flow wings. Laminar air flow over the wines is insured by I'lush rivets attaching the leading edge or'the "wraD-around" wing skins. Wing construction features multiple ribs attached to main and stub s_Dars incorPorating aluminum spar caps.
4, ~TSEL4GE
The cabin suDersuucmre is built of 4130 ntb~ilar steel and covered with non-structural aluminum skins. The taTZ section (baggage com_oanmem and aftstruoture) has a stressed-skin semi-monoco$re design. Aluminum skins are riveted to heat-treated alumimun bulkheads with extruded aluminum stringers reinforcing the tail cone sectioh
5, EMPENNAC~
The empennage is constructed on qDtically aligned jigs to insure uniformity and close tolerance fit for all parts. Construction is of sheet metal, riveted to formed ribs and s_Dars. To provide srabi- lizer trim, the entire empennage pivots around the tail cone attachment points.
6. LANI~INCGEAR
The landing gear is unicpe in ~hat it is manually retracted by the pilot. Gear-assist s_Drings in the wings, aided by bungee springs in the fuselage, make manual o_Deration of the gear cIuite simple. Gear-mounted rubber discs are used for shock absorption. Grease fittings are provided at important lubrication points on the landing gear, The standard M20D has a fixed landing gear, but can be con- verted to a retractable gear identical to the M20C gear system. Electrically ooerated gear retrac- ing systems are optional for all models.
7. ~RAKESYSTEM
aydraulic disc brakes are featured on all models. The hydraulic fluid reservoir is located in the inside upper left-hand area of the firewall. Toe-actuated rudder_oedals operate the left and right main gear brakes independently. Dual brake systems are optional for all models.
1-2
Island Enterprises 8. FL3GHT CONTROLS
The ailerons, elevators, and rudder are of an all-metal jig-built construction incorporating hinges of machined extrusions, Push-pulltubes, rather than the conventional cable systems, are used to actu- ate the control surfaces.
9. FMPSYSTEM
The wide-span all-metal flaps are hydraulically controlled by a hand-operated pump which actuates a hydraulic cylinder., it relief valve is provided which releases hydraulic pressure at a slow rate as retraction springs (or air pressure) raise the naps. Ihehydra~lic fluid reservoir is common to both the brake and flap systems. Maintenance of the fla_o system is similar to the brake system.
10, TRIMSYSTEM
X small control wheel on the floor between the front seats actuates the adjustable stabilizer via a ~ar reduction box and torque tube Linkage which actuates the empennage jack screw. The torcIue tubes are connected by universal joints and are supported by-formica guide blocks.
11. NELSESTEM
The fuel system consists of integral fuel tanks located in the front inboard portion of each wing. These tanks are Formed by setling off a portion of the wing through the use of a special sealir;g com- pound. Fuel is fed from the wing, to a tank selector valve, on to an electric boost pump and then to the engine-driven iuel_oumo and fuel injector or carburetor.
12. mSTEM
The electrical system is provided with a 50-amp 12-volt generator and a 3S-amp/hour battery. AII electrical systems can be turned off with the master switch which actuates a relay located at the battery, Circuit breakers are provided on the lower right side of the instrument panel. Standard equipment includes a 250-watt landing light, navigation lights, interior lights, an electric starter, gear and stall warning systems, and an electric boost pump.
13, INSIlltTMENT Pi\NEL
The instrument panel has been designed to provide functional location of all flight, radio, and engine instrument grouDs, The flight instiumems onthepilois side are installed in a rubber shock-mounted Danel to reduce;ibrztion transmission to the instruments.
14. HEATING, VENTIL~TION. AND DEFROSTING mSTFMS
Cabin heat is obtained from a muff which surrounds the engine exhaust manifold. From the muff a flexible duct transmits heated air to a junction box zft of the firewall on the co-pilors side. Cold air is also ducted to this junction box from the flush air scoop on the right side of the airplane. The hot and col~ air entering the junction box can be controlled to provide the combination required for the desired tem_Derature. From the junction box, air is ducted to the piler and co-pilot's feet, wind- shield defroster, and rear cabin.
15, SZ.iiTS
X11 seat backs are contour formed. The seats are padded with plastic polyfoam and covered with durable u_dnolstery. The from seats have a three-position reclining adjustment and are adjustable fore and air on the floorboard seat rails. The rear seat back may he removed to provide a larger cargo area.
1-3
Island Enterprises D. SPECIFICATIONS OUTLINE
1. ~NGINE
a, M20C:
Model 0-360-A1D F4A Type Certificate 286 Rated Horsepower and Speed (RPM) 280 at 2700 ProDeller Drive Ratio 1:1 ProDeller Shaft Rotation Clockwise Bore (Inches) 5.125 Stroke (Inches) 4.375 (Cubic Inches) 361 ComDression Ratio 8.50:1 (witfi Starter and Generator) 284 Dimensions: Height(Inches) 24.59 Width (Incl?es) 33.52 Length (Inches) 29.81 Oil Sum_b Capacity (Quarts) 8 Fuel Oc;ane b. M20D: The 0-360-A2D Lycoming engine is basically the same as the 0-360-A1D engine ex- ce~t that the 0-360-~2D engine has no constant-speed propeller governor. c M20E: Model I0-360-A1A E~A Type Certificate 1E10 Rated Horsewwer and SDeed (RP~VI) 200 at 2700 ProDeller D;ive Ratio 1:I Pro'beller Shaft Rotation Clockwise Bore (Inches) 5.125 Stroke (Inches) 4.375 Disdacement (Cllbic Inches) 361 Com~ression Ratio 8.7:1 Dry Weight (witfi Starter and Generator) 323 Dimensions: Heighn(Inches) 26.61 Width (Inches) 34.25 Len,oth (Indhes) 29.81 Fuellnjector (Bendix) RSA-5ADI Firing Order 1-3-2-4 25 Spark Occurance @egrees ETC) Valve Roc~4er Clearance (Ta_qDets Collapsed) 0.028" to 0.080" 8 Oil Sump Capacity (Ouarts) Fuel Grade) 100/130 Octane~(Aviarion S4LN-204 Magnetos (Beradix) (Right) S·ZLN-200 (Left) 0.5:1 Tachometer Drive (Rztio to Crznkshait) Rotation Clockwise I3.55:1 Starter Drive ~iiado to Crankshaft at ~endix Drive) (Counterclockwise) 1-4 Island Enterprises Starter (Geared 3.38:1) 12 Volt Generator Drive (Rado to Crankshaft) 2.50:1 Generator (Delco-Remy, 12 V) 50 AhlP A-N Vacuum Pump Drive (Ratio to Crankshaf~ and Rotation) 1.30:1 (Counterclockwise) Pro_Deller Governor Drive AS20010 (Type XX) Ratio to Crankshaft and Rotation .Srib':1 (Clockwise) FuelPump AC(TypeJT) 2. OVER-ALL Wing Span 35 ft. 3 ih Length (M20C,D&E) 23 ft. 3 1/2 in. Len~h (MZOF) 24 ft, 0 in. Height 8 ft. 4 1/2 in. Clearance (Prqoeller'lios) 9 3:'4 in. (Approx.) 3. 2, Standard X120C.S.&F Type Manually Retracted Tread 9 ft. 3/4 in, Main Wheel Type Cleveland Air Products Main Tire 6 Pl)F,F100 x 6 Main Tire Pressure 30 pounds Bra~te Type Cleveland Hydraulic 2luid Required Hydraulic (MIL-0-5606 Red) Cleveland Air Products Nose Type 4 5:00 X 5 Nose Tire (MZOC.D,&E) Ply, Nose Tire (120F) 6 Ply, 5:00 x 5 Nose Tire Pressure 30 P3I Nose Tire Pressure (5120F) 49 PSI Electric gear retraction kits are available from Mooney distributors. b, Standard M20D: Type Fixed Other specifications are same as M20C E aircraft. Retractable gear is optional on all ~v120D aircraft; conversion kits are available from Mooney distributors. L1. F~TEL CAPACIIIES 48 total M20C [1962-1963) gallons 48 total M20D (1963) galIons total hi20C (1964 ON) 52,oaLZons total M20D (1964 Oiu3 52,oallons 52 total M20E (1964 Oh3 gallons X120F (1967 0~3 64 gallons total 5. WING span 35 Ft. 0 in. Length of Flap (Trailin,o Edge) 10 ft. 8 in. Length of Aileron (TrailingEdge) 5 rt. 3 1/4 in. omearzl (Lezdin,o Edge) 5"30 minutes Incidence, 2"30 minutes Airfoil Section at Root NXCA 63-215 Airfoil Section at Tip ~IEOC,D.&E) NACi\ 64-412 Airfoil Section at Tip (hP-GF~) NACX 64-412 ~lod. Area wing 167 sq. fr. Aileron Area 11.2 sq. ft. Flap Area 17.2 so. ft. 6. EhlPE~TNACZ Vertical Fin Area 7.9 sq· ft, Rudder Area (XIZOC.D,&E) 5.01 sq. ft. Rudder Area (M20F) 6.23 so. ft. 21.5 ft. Horizontal Stabilizer Area sq. 12.0 it. Elevator Area sq. 1-5 REVISED NOVEMBER 1966 Island Enterprises TABLE 7 PROPELLER AND GOVERNOR SPECIFICATIONS Std, for M20C Opt, far M20C Std. for M20C Opt. for M20C 1962-1963 1962-1963 1964 1964 s/lt 1940-2622 S~ 1940-2622 S/N 2623-2806 SM 2623-2806 Manufacturer Hartzell McCauley Har~ell NIcCauley Type Constant Speed Constant Speed Constant Speed Constant Speed Hub RC--22YE;--1 2D3~C53-A HC-C2YI~--1A 21)34CS3--A i4Eu 7666--2 743--8 Woodward: Hartzell: Woodward: D--l~ (1940C-24MXC 210452 D--1'-6 (2623C"704C) 210452 o-la (2401(=-2622(3 H--l (2705C-2806C) Blade Angle, Low 130 12.7" r 20 130 3 0' ',2.7" t 20 Blade Angle, High 290 i~ 20 27.50 I .050 290 z 20 27.50 1..050 Std. for M20C Sid, for M20C Std, for M20C Std, for M20C 1965 1966 1966 1967 SlN 2807-3184 S~ 3185-3230 SM 3231-3466 S~i 670001 g ON Hartzelr Hartzell Hanzell Hartzell ~Spe Constant Speed Constant Speed Constant Speed Constant Speed Hub HC--C~YIC--IA HC-C2YIC-IA HC-C2YIC--1B HC- CZYK--1B Blade 7666--2 7666--2 7666--2 1 7666--2 Prop. Governor Hartzell: r Har~ell: Haruell: Hartzell: H-r H-l H--L H--1L If--IL H--1L H--IL Blade Angle. Low 130 I 0" 130 3 00 130 00 130 f 00 Blade ~ngle, High 290 20 29",' 20 2P~ 20 290 20 Srd, for M20D Std, for M200 Opt, for M20D Opt, for M20D 1963 1964-1967 1964 1965 g ON SM 303-200 Sntiol-z60 SM 201·251 S/N 252 g ON Manufacturer Hartzell ~cCauley Hartrell Haruell Tgpe Constant Speed Fixed Pitch Constant Speed Constant Speed Hnb lC173 HC-C1YIC--1A HC-CZY~--LB Blade 7666--2 41FA74d0 1 7666--2 7666-2 Prop. Governor Hartzell: i I Hartzell: Hartzell: 0--1--4 (1011)-1230) 1 i I)--r--4(101D--123D) H~ D--16 (124D-220D) D--1--6 (1241)--2201)) H-rL Blade Angle, Low 130 O0 130 00 130 00 Blade Angle. High 29" s~ 1 1 29"=20 290 r 20 Std, for M20E Std, for M20E Std, for M20E Std, for M20E 1964 1965 1966 1967 Si~ 101-169 s~ 470·831 S~ 832-1308 SM 670001 g ON Manufacturer Hartzell Haraell Hartzell Hartzell h~pe Constant Speed Constant Speed Constant Speed Constant Speed Hub HC--7-YK--1A CHC--CZYK--1A HC--C?YIC--I HC--C'YK--I HC--C2YK--1 Alternate Blade 7666-2 17666--2 7666--2 7666--2 Prop. Governor Hartzell: I Hartzell: Hattzell: I)--16 (102E--303E)I H--l H--l H--l' H-2 (304E--169E) H--IE Blade Angle. Ipw 140 I 00 14" ~:00 rC C oO 140 i· oO Blade soO i 7'C Angle. High 1 2p' i:30 29U ~:2C 7-90 _ 20 Srd,forM20F 1967 Sr~ 660003 S.iN 670001 g CN Manufacturer f Hartzell ~-pe Constant Speed Hut, HC--3YEi--1 Blade ;666--2 hop. Governor Hartzen: H--1L Blade Angle. Low ~O I OJ Blade Angle. High 19J r ?O REVISED NOVEMBER 1966 1-b Island Enterprises FIG1IRE 1-7 M20C (1962-1964) THREE V1 -c------It 9 -----r: I ;1/ 35 3 3C7~_ t-- 9 ;----r I 8'4f 7 1-7 Island Enterprises FIGURE l-1A M20D (1963-1964) THREE VIEW O j Ooo_ 1-8 Island Enterprises FIGURE 1-1B M20E (1964-1965) THREE VIEW 1-3 Island Enterprises FIGURE l-1C M20C (1965) THREE VIEW '3 i 7~1 1-10 Island Enterprises FIGURE l-1D M20D (1965) THREE VIEW B I\ p 1-11 Island Enterprises FIGURE l-1E M20C (1966 a ON) THREE VIEW I-, I 1-12 REVISED NOVEMBER 196S Island Enterprises FIGL'RE 7-1F M200 (1966 ON) THREE VIEW i I REVISED NOVEMBER 19L6 1-13 Island Enterprises FIGURE I-1G M20E (1966 ON) THREE VIEW ~1 n REVISED NOVEMBER 1966 1-14 Island Enterprises FIGURE l-1H M20F (1967 a ON) THREE VIEW 35'3" Et,,~ I 24" i 13 9~-" REVISED NOVEMBER 1966 1-15 Island Enterprises SHOP NOTES 1-16 Island Enterprises SECTION HAND LING AND SERVICING Island Enterprises SECTION II HANDLING SERVICING A. GENERAL This section provides ground handling and servicing instructions. B. ACCESS PROVISIO~S Figure 10-1 shows the location of the access panels and plates that provide access for purposes of service and maintenance. C. HANI)L3h~G The following instructions are recommended to avoid damage to the airplane during ground opera- tions. If improperly handled, extensive damage to the airplane and its equipment may result. The airplane may be taxied as required for normal maneuvers. Brakes or rudder pedals may be used for turning. If a towbar is used, one man may move the airplane providing it is on a fairly smooth level surface. Points where pushing the airplane are permitted are leading edge of the wing, wing tips, and the inboard position of the propeller blades adjacent to the propeller hub, i. Jacking When it is desired to raise the airplane off the ground to check operation of the landing gear, the following jacking procedure is recommended. By using jackpoints provided outboard of each main gear (Figure 2-1), it is possible to use standard aircraft jacks to raise the main gear off the ground. A yoke-frame jack may be used under the propeller. Care must be taken not to damage the pro_Deller or spinner. The nose may also be raised by anchoring the tail skid tfe- down ring to a fixed point in the shop floor while jacking the aircraft at the wing hoist points. 2. hiooring When mooring aircraft, the following method is recommended. Place chocks fore and aft of each main wheel. Stakes may then be driven in the ground outboard of each main gear, approx- imately three feet, and at the tail skid location. Tie down rings are provided, two feet outboard of each main gear, at the jack point. A tiedown ring is also provided at the tail skid location. 3. Towing A suitable towbar is provided as standard ec(uipment with each airplane. The lower bar of the towbar is placed t~rough the gear spindle upper crossmember. Care must be exercised that the nose gear is notrotatedpastits normalswivel angels. Towing with a tractor or by other mechani- cai means is not recommended. Note: See that parking brake is off before towing airplane. REVISED NOVEMBER 1966 2-1 Island Enterprises FIGURE 2-1 JACKING ~ACI< POINT TII DOWN RING FIGURE 2-2 LEVELING a~7 ~i slst~ '"~c: t:?-~ r'i :i-";:""'" a 2-2 Island Enterprises FIGURE 2-3 PLUMBING :r s~T ~I· i r~ ii 3. Pi·· I -~1 L;: c~ 4. Leveling level on the tail cone skin splice above Longitudinal leveling is determined by placing a spirit be made increasing or decreasing air pres- the access door. 2-2) Adjustments may by (Figure of scales for when the is on the or on a set weighing. sure in the nose wheel tire airplane ground Drained) 5. ~Teight Balance (Fuel and Oil in the Balance Data form or Weight Check installed ec~ioment using the Ecluipment List Weight each of the three wheels. Place a ramp on each Record. Position a s~ale in front of Balance the air- the scales. Remove the ramps and proceed to ~Yeigh scale and tow the alcr~fr up onto bob from centerline of the nose gear attach craft when level. Find the datum by dropping a plumb axle locations from and then mark the floor (see Figure 2-3). Measure bolts (retracting axis) in Record the weight at each urheel as shown this mark (See Figure 2-3A or Figure 2-3B). Record the distances between points as shown in figure 2-3A and 2-3B. Total the weights. forward of the main wheels. Compute the CG's Fus. Figure 2-3A and 2-3B. ComPute the CG and CG in section III of Weight Balance Record or Sta. aft of datum. Post empty weight equivalent`tireight Balance Data form. 2-3 REVISED NOVEMBER 1966 Island Enterprises FIGURE 2-3A WEIGHT BALANCE COMPUTATION (M20C,D,&E) HORIZONTAL DATUM NOSE GEAR TRUNION W~NT STA O ~r? n WEIGHT ELst:L LEFTMAINWHEEL WmA Wm/l W W N kYR NOSE WHEEL W, W MfL TOTAL WEIGHT Wt a. CG Forwardof Main~heels: LBS. LBS. IN. X Weight of Nose Distance Between Total Weight CG Forward of Main and Nose Wheel of Aircraft Main Uheels Axle (WN) Centers (LN/H) (WT) (LM) b. CG AZt of Datum (Station Of: IN. Distance from Center Result of CG (FUS. STA.) Distance Nose Gear Trunion to Computation Aft of Datum. Center of Main W'heel Above (Empty Weight CG) Axles (Horizontal) (LM) (Ly~) 2-3A REWSED NOVEMBER 1966 Island Enterprises FIGURE 2-38 WEIGHT a BALANCE COMPUTATION (M20F) BEfFPOINT BO-SIZONTAL ~OSE GEAfl IIATUMS~AO TR~NION I: S~A -j) %1 C[C3 WEIGBT ii 11)5~ tEFTMAINPTBEEL LM,C~ ---L W~ w, 1NYfi RIGHTMAINWBEEL W M/t NOSE ~HEEL W, TOTALWEIGHT W1 a CG Forward of Main Wheels: LBS. IN. LBS. IN. X Weight of Nose Distance Between Total Weight CG Forward Main and Nose Wheel of Aircraft of Main Wheels Axle Centers (Wu) (W,) (L.) CG Aft of Datum (Station O): IN. 5 N. IN. IN. Distance from Center Distance from Result of CG (FUS. STA.) Nose Gear Tnmion to Nose Gear Trunion Computation Distance Aft Center of JIIain Wheel to Datum Above of Datum. Axles (Horizontal) (Empty Weight CC) Con.tant (LM) (L~) (LC/G) REVISED NOVEMBER 1966 2-38 Island Enterprises D. SERVICISC 1~ FU~LSYSTEM a. Fillingrheiuelr~nks(L964 bOS! Each wing integral fuel tank has a ca_oacity of 26 t'S. gallons (32 gallons for M20F models) and is accessible for filling by flipping the filler cap latch up and turning it to release the cap. A vent is pro~ided at the outboard forward corner of the tank to compensate for fuel expansion, depletion, and ove,nlow. A fuel sumr, drain is located on the inboard corner of each wing tK~k. This is the lowest point of each f;el tank. NOTE: Visual fuel level indicators at the 25 gallon level are installed in both tanks on Z~f?OF models 5~ 670074 3i OS. 1962-63 MZOC 1963 B~ch wfng imegral fuel rank bar; a crpacj· Q124 U.S. gallo~ and it acce~sihle Far iillfng by lifting a door and removing the exoansion-type gas cap. A scuDDer-box drain is provided to drain off any gasoline spilled outside the filler neck opening. C~UTION: Aircraft and fuel seNice vehicle must be grounded when refueling the aircraft. Ground servicing nozzle to aircraft wing. No smoking within SO ft. of aircraft or vehicle. b. Drainingfuelsystem To drain fuel from the syst~n, disconnect fuel line at electric boost pump, attach another Zlex line leadino to a drain barrel, and turn boost pump on. The fuel will be pumped out of the ranks throuifh the boost pump. Fuel tanks may also be siphoned as an alternate method. Aircraft and barrel must be orcunded. Allow no smoking or open flame within 50 ft. of air- craft. Fire extinguisher (foa~ type) should be immediately available. c. Strainer removal Remove and clean the following nrainers every 50 hours: ~SCOMTOR (Located in the nose wheel well) OILT ELECTRIC BOOST PUMP 1963 (Loczted under floorboard) FUEL-SEI~CTOR VALVE 2-4. (Located beneath the rloorboard Figure All M20 series aircraft in the from portion of the cabin) j d. Drainingselecrorvalveand fueltanksum_Ds To check for water and sediment in the fuel system or to completely drain the fuel system, the sumps may be drained as follows: Wing Tanks: insert prong of Plastic cuD (suDolied with each aircraft) into the drain hole at the rear inboard side of the fuel ranks an~ press upward. Selector Valve: Pull ring adjacent to selector valve inside the cabin. Switch valve handle to right and left tanks to drain resbective lines. On 1962-63 M2OC and 1963 N20D aircraft, drain fuel selector valve on under side of fuselage using the plastic sampling cup. 2. ENGINE Lt'BRICXTION a. Filling engine sum_o Fill engine sum_r, (Figure 2-3) with lubricating oil specified on the lubrication chart (Figure 2-9). b. Draining enginesump The engine sump can easily be drained by means of the oil quick drain that is installed on each engine as standard (Figure 2-6). 2-4 REVISED NOVEMBER 1966 Island Enterprises FIGURE 2-4 FUEL SELECTOR VALVE ASSEMBLY ;3i ~ss STRAINER Z~"ri: FIGURE 2-5 OIL DIPSTICK ACCESS r F1 Q 2-5 Island Enterprises FIGURE 2-6 OIL QUICK DRAIN (M20E) z -7 r~zl ~21 FIGURE 2-7 011 SCREEN SiRAINER LOCATIONS lM20E) s·~ ·i. I g I: i· s~· ~e :w OIL PRESSURE SCREEN THERMOSTATIC OIL COOLER REAR VIEW OF ENGINE BY-PASS VALVE (REMOVE g CLEAN EVERY 50 HOURS) OIL SUCTION SCREEN (REMOVE g CLEAN EVERY so HOURS) 2-6 Island Enterprises c. Cleaning oilscreen strainers Remove two strainers (Figure 2-7) and flush with kerosene every 50 hours or each time oil is changed. (MZ0E&F) 3. BRAKESYSTEM The brake cylinder reservoir must be filled with the brake fluid specified in Figure 2-9. The reservoir fluid level should be checked at every 50-hour inspection and replenished as necessary. After a periodic installation, the brakes require no adjustment during the serv- ice life of the brake lining. CAUTION: Do not fill reservoir while parking brake is set or when flaps are extended. (See page 5-15 for brake bleeding procedure.] 4. BATTERY Check battery fluid level and battery condition every 25 hours. Use only distilled water when servicing; avoid comaminarion of cells. 5. INDUCTION SYSTEM Check air filter visually at each pre-flight inspection. If cleaning is necessary, remove filter and clean in accordance with Section III C. Check power boost door seal(MSOE&F). 6. VACtUM STEP SYSTEM (1965 Models and subsequent) A vacuum servo will raise the stC~p when the engine is started and sufficient vacuum is Produced. A spring will pull the step down when the engine is stopped and vacuum is relieved (Figure 2-8). NOTE: To lubricate the step strut, spray a light coat of a Silicone-type lubricant on all four sides of shaft. This substance will not attract dust or soil clothing. E. LUBRICATION Refer to Lubrication Diagram (Figure 2-9) for instructions regarding lubrication points, intervals, and type of lubricant recommended. Crease finings are provided on the nose gear and main gear. Bearings used in bell cranks, hinge points, and rod ends should be l;bricated periodically to prevent corrosion. Avoid excessive application of lubricants. Excess lubricant onemerior surfacesof bearings tends to attract dirt and grit and may lead to malfunction of the unit. Where a reservoir is not provided around a bearing, gpply the lubricant sparingly and wipe off ex- cess. Remove wheel bearings from the wheel hub and clean thoroughly with a suitable solvent. When repacking with grease, be sure lubricant enters space between rollers and retainer ririg. Do not pack grease into wheelhub. (See Fig~re 2-9 for recommended lubricant.) Whenever specific instructions for lubrication of mechanisms are not available, observe the follow- ing precautions: I. Apply oil sparingly, never more than enough to coat bearing surfaces. 2. At the regularinspection intervals, squeeze the magneto cam follower felts with the fingers. If oil appears on fingers, do not add oil to the felts. If felt is dry, moisten with light oil. Be careful not to add too much oil, because an excess will be thrown off during operation and will cause pining and burning of magneto points. Refer to Lycoming Service Instruction 1014 (latest revision) for engine oil specifications. REVISED NOVEMBER 1966 2-7 Island Enterprises FIGURE 2-8 VACUUM STEP SYSTEM INSTALLATION (1965 MODELS AND SUBSEQUENT) AN 364- 524A N1/7- 11691 WASWER CZ, ANJ64-S~4A NUT 17691 H'AS~IER SEI~YO 11660-/ STRRP AN 3-ba tiYXrr PoLLEY ASS)I AN960-/0 WAdl·ltX aNSsr-/o3za Nor AN 5-SA BOLT STRING T/E EiVD C4" TUBE NAS 5~57- 4A GRoMMET Ai~L3-3 BcrT 1Nsrc-/o v~nEA NUT SnrmWR JCRYO PVLLY ASJ1I lorr 739-rr-12-~ 7 CLIYP V /I ~IWliZP BOLT AHSbD-K) W~FHEA AKJ-CI NUT IXSCO-ld VISHDT(tl Nvr CUP ~7 GALV TH/MSLr ;G NAJO-PREfS S~LEYE- ANIW-J 7H/HB12 8f~Ua KN/tO-P~E?iS AMN JlrOP BEAR/NG *N ·It- ~24EYEBLXT BLOCK AN Jb~-/OJL NLlT SNSLI;ZB cwJ-zsa IW ~60-l,b AN 960- LWISHER 1N 565-9~8 NM D D/REC~ONAL GYRO SERVO CovER TREno 2-8 REYISED NOVEMBER 1966 Island Enterprises FI EXTERIOR ~NTERIOR CARE As with any palm applied to a metal surface, an initial curingperiod is rec~ired to develop the desired ~Iualides of durability and appearance. Therefore, wax or polish should not be applied to the exterior until two or three months after delivery. Wax substances will seal the paint from the air and prevent curing. Hold buffing to a minimum until curing is complete and there is no danger of disturbing the undercoat. Before washing the e9terior, be certain the brake discs are covered, thepitot shield is in place. and both static air buttons are masked off. Loose dirt and mud deposits should be flushed away aircraft before washing the exterior with an detergent and cool water. Use soft cleaning cloths or a chamois and avoid harsh or abrasive detergents thatmight scratch or corrode the surface. To remove a heavy oxidadon film, use a prewar cleaner (example: HarlyCarnuba). For nonoxidized or pre- cleaned surfaces, apply a good exterior-finish wax (example: Harry Wax) recommended forpro- tection of acrylicenamel finishes. Follow the manufacturer's instructions carefully. Aheavier coating of wax on the leading edges of the wings, empennage, and nose section willhelp reduce drag and abrasion in these areas. If fuel, hydraulic oil or any other fluid containing dyes ia found on the exterior paint, wash the area at once to prevent staining. Spilled battery acid must be flushed away immediately and the area treated with an alkali and water solution followed by a thorough washing with an aircraft detergent solution. Household window cleaning compounds are not recommended, as some contain abrasives or sol- vents which could harm the Plexiglas. Furthermore, it is essentialthat allcleaningcompounds and application cloths be free ot abrasives, grit, or otherforeignmaaer. Never usedenantred alcohol, benzene, carbon tetrachloride, acetone, or leaded gasoline for cleaningPlexiglas or in- terior plastics. Before wiping the window surfaces, flush the exterior with clear waterto remove panicles of dirt. Grease or oil can be removed by wiping the panel with a cotton cloth saturated with unleaded gasoline or kerosene. An anti-static Plexiglas cleaner is recommended for cleaning and polishing the windshield and windows. Normal household cleaning practices are recommended for routine interior care. The seats, rugs, upholstery panels, and headliner should be frequently vacuum cleaned to remove as much surface dust and dirt as possible. The fine leather or vinylupholstery and kickpanels need occasional washing with an aircraft deteroent solution to prevent the working of dirt into the surface. Wipe clean with a slightly damp cloth and~rywirha soft cloth. Never apply furniture polishes. Foam type sham- poos and cleaners (example: Garry's VLP) for vi?yl, leather, and plastic materials can be used to remove stains and to condition the entire interior. Spray-on dry cleaners are also recommended. When using commercial cleaning and finishing com_oounds, carefully follow the manufacturer's in- structiorts. Never saturate fabrics with a solvent which coulddamagethebaciting andpadding materials. To minimize wetting of carpets, keep foam as dry as possible and rub gently in circles. To remove foam, use a vacuum cleaner. Royalite, vin~jl, and metal surfaces may be cleaned with a damp cloth or an aircraft detergent solution. Do not use alcohol or strong solvents on Royalite plastics. 2-9 Island Enterprises SHOP NOTES 2-10 Island Enterprises 2 3 7 8 9 10 11 6 20 19 12 13 14- 15 ,Is ',5 'B '12 o b o o o o o I- o ~1 9 O 00 o_ POO O 010 OO 30 SO 21 21 30 30 18 27 27 16 18 16 22 o I o O\IO 30 30 30, 1 .23 24 25 26 9 28 27 29(vl 4 Figure 2-9. Service, lubrication, inspection access guide. REVISED OCTOBER 1975 2-11 Island Enterprises ACCESS COVERIDENTIFICATION LUBRICATION GUIDE ~PTEM ~EM DESCRIPTION LUBRICATION MTERVAL NO. SYMBOL* (HRS) 1 Propeller 0 100 Starter Drive 1~ 20 2 BATTERY (M20 C D) 3 Flight Instruments Positive Control Pilot Valve Vacuum Regulator Turn Coordinator Vacuum Filters--Replace at 500 Ifydraulic Reservoir. 0 50 Control System Adjustments: Control Column Beari~g Ball 100 Rod-End Bearings 100 Universal Joints 100 BellCranks... 100 4 Engine Cowling 5 Nose Gear Grease Fittings 100 RetractionTube 100 BellCranks 100 Bungees 100 Shock Absorber 100 Gear Door Rod-End Bearings 50 6 Main Gear Grease Fittings 100 Retraction Tube Rod-End Bearings...... ,, 1 100 Bell Cranks 100 Bungees 100 Gear Door Rod-End Bearings 50 Electric Gear Actuator Gear Boir. 100 Electric Gear Actuator BallScrew 100 Elevator Rudder Controls: Control Tube Rod-End Bearings 100 Bell Cranks. 100 P.C. Servos Baftery(M20E F &J1~ Baffery Relag IM2~, F, J) Retractable Step. 100 Stabilizer Trim Control Shaft: Universal Joints ~L 100 Guide Blocks.. 100 8 Elevator Rudder Controls: Control Tube Rod-End Bearings....,.,.... 100 Bell Cranks ~L 100 Stabilizer Trim Jack Screw. 100 9 Empennage Attach Points 100 Stabilizer Trim Attach Point 100 10 Elevator Rudiler Controls: Control Tube Rod-End Bearings...... 1 100 Trim Assist Bune~ee Attach Point 100 *See last page of section for lubrication symbol legend. 2-12 REVISED JULY 1980 Island Enterprises ITEM DESCRIPTION INTERVAL XTO. SYMBOL* (HRS) 11 Elevator Rudder Controls: Control Tube Rod-End Bearings 1 100 Trim Assist Bug~ees I ~L 100 Elevator Down Springs 100 12 Aiferon P. C, Servos 13 Aileron Controls: Control Tube Rod-End Bearings 1 100 Bell. cranks...... 1...... 100 100 14 Aileron Control T~ibe G~ride Blocks 100 15 ~Aain Gear Retraction Spring...... ,.... 100 16 tT~Tin3oAttach Points ControlTube Grride Blocks 100 1? Hydraulic Flap Pump TdnF~oe..,...... 100 Stabilizer Trim Screw Stops 100 Indicator Adjustment Point Stabilizer Trim Chain Gears. 1 100 18 Elevator Rudder Controls: ControlTube Rod-End Bearings 100 Bell Cranks 1, 100 100 Hydraulic Flap Cylinder Rod-End Bearing. 100 Flap Indicator Cable 100 Electric Flap Actuator Gear Box. 200 Electric Flap Actuator BaLlScrew: 100 19 Electric Boost Pump. Fuel Selector Valve Detent Track Ball 100 20 Control Systems: Control Tube Rod-End Bearings 100 ControlYoke (Lower Section); 100 Nose Gear Steering Link 100 Rudder Pedal Cross Shaft...... ,..., 100 Rudder-Aileron BuIgee 100 Hydraulic Brake Cylinder Pedal Linkage...... 1, 100 21 Aileron Control T~e Rod-End Bearings. 1 100 Orrtboard Flap Stops 22 Retractable Step 1 100 23 Baggage Conpartmerrt Door: iiinges 100 Latches n 100 Seals 0 100 24 Cabin Door: Hinges 100 Latches a 100 0 100 hold-OpenArm 100 *See last page of section for lubrication symbol legend. REVISED JULY 1980 2-13 Island Enterprises rT~ M ITEM DESCRIPTION LUBRICATION INTERVAL NO. SYMBOL' (HRS) 25 Engine Instruments Radios 26 OilDip Stick. ~f 27 Wheels Brakes: Wheel Bearings. O 250 Brake Pressure Plate Anchor Bolts...... ,, 50 28 Elevator Rudder Control Stops 29 Nose Wheel: Wheel Bearings. O 250 Shock Absorber. 100 30 ControlSurface Rinoes 100 LUBRICATION SYMBOL LEGEND SYMBOL MIL. SPEC. NO. DESCRIPTION 1~ MILE?870 Low Temperature Oil (General Purpose) MIEG-??11 or MILG-81322 Grease C3 MILL3545 ...... Grease Temperature) O MILG-23827 or Hartzell DG Grease O MIGH-5606 ...... Hydraulic Fluid (Red) Graphite MIEG-3278 Grease or MILG-23821 O Powdered Graphite Ter'lonSpray ~Tri-Flon) n ..Stick Lubricant @oor Ease or Equivalent) ..Standard OilAviation Grease No. 5 With Id~e by Volume Molybdenum Disulfide or MILG-23827 AMI Lubriplate 630~ (10C~ by Volume Molybdenum Disulfide Mixture Permissible) O 1$3 ENGINE OIL RECOMMENDATIONS For All Lyc0min~ Aircraft Engines Average Ambient Single Operating Air Temperature Viscosity Multi-Viscosity OilInlet for Starting Grades Grades Te OTE II*) I RTOTE m~ I Desired Maximum Above 600F SAE 50 SAE 40 or SAE 50 1800F 2450F SAE 40 SAE 40 1800F 2450F 700F900F S-4E 30 SAE 40 or 20~Y-30 1800F Z25~F Below 100F SAE 20 SAE 20W-30 1700F 210"F *Refer to the following page for Notes I, II III. 2-14 REVISED JULY1980 Island Enterprises NOTES: ENGINE OIL RECOMMENDATIONS MODELSAFFECTED: A11Lycomingopposedseries aircraftengines TIME OF COhlPLIANCE: Any time after initial 25 hour preservation run or whenlubricating oil is changed or added. Engine lubricating oil viscosity recommendations are on. RECOMMENDATIONS FOR NEW shown on the previous page. However. the over-all ac- ENGINE BREAK-IN ceptance of derer~ms. compounded, or additivelubri- oils is not sui"nciem reason for caring recommending New, or newly overhauled engines should be oper- their in aircraft Inferior base use Lycorping engines. ated on straight mineral oil during the first 50hours oils are sometimes doctored with to detergents disguise of operation, or until oil consumption has stabilized, if their true characteristics; there are oilsthat an additive detergent oil is used in a new engine, or a newly over- can cause spark plug fouling and preignirion; and there hauled engine, high oil consumption might possibly be are those that are incomoatible with other oils. But, experienced. The anti-friction additives ofsomeofthese of such factors, there are some aviation ad- regardless oils will retard the break-in of the piston rings and cyl- ditive oils that appear to be supMor in performance to inder walls. This condition can be avoided bythe use mineral oil, and their use in aircraft straight Lycoming of straight mineral oil until normal oil consumption is Is recommended. Included fn these oils engines are obtained, then change to the additive type. the multi-viscosity ashless dispersant oils essentially to MiL-L-228j1 conforming Specification exceptforcor Preservative oil should be removed at the end of the net seasonal suitable to viscosity grade Lycomtng first 25 hours of operation-it must never beused beyond series engines. 50 hours. When adding oilduringtheperiod preservative oil is In the engine, use only avfationgrade straight min- eral oil of the viscosity desired. CAUTION· Any lubricating oil, Either straight mineral or must conform compounded, withlycom- RECOMMENDATIONS FOR CHANGING OIL ing Specification No. 301~ to be acceptable for use in Lycoming aircraft engines. Proof In engines that have been operating on straight min- of such conformity is the responsibility of eral oil for severalhundred hours, a change to additive the lubricating oil manufacturer. oil' should be made with a degree of caution, the clean- Ing action of some additive oils will tend toloosen and NOTES sludge deposits cause plugged ollpassages. When an engine has been operating on straight mineral oil, and is ~cnown be I AVERAGE TEMPERATURES The listed ambient to in excessively dirty condition, the switch to additive or compounded oil should be deferred ground air temperatures are meant only as a guide. Ac- until after the is overhauled. tually a great deal of personal Erdgment must be used engine wben selecting the seasonal grade on to put into the When from mineral oil to com- engine. For example if a plane is to be flown into an changing straight pounded oil, the should area which is much warmer or much colder, only per- following precautionary steps be taken: sonal judgnem on the parr of the opelator can determine what grade of oil to use. When oil inlet temperatures i. Do add additive oil approach the maximum allowable dnring operation, it is nor to straight mineral oil. Drain the mineral oil from the and fin a good indication that a higher viscosity on should be straight engine considered. with additive oil. 2. Do the n SIh'CLE VISCOSITY GRADES This classification not operate engine longer than five hours before the first on of lubricating oils includes any aviation grade (straight change. miwrsf, detergent and dispersam) that is designated 3. Check all oil screens for evidence of by a single viscosity number. The SAE Grades 20, 30, sludge or plug- oil ten hours if conditions 40 and 50 shorm in the chart are equivalem of Grades ging. Change every sludge are evident. 55, 65, SO and 1M) respectively. Resume normal oil drain periods after sludge conditions improve. m MULTI-VISCOSITY GRADES This classification includes additire oils with viscosities the same as straight mineral oil at high temperatures, but which provide a lower at low The viscosity temperatures. CAUTION additives in these oils extend operating temperature range. impro~ing cold engine starting and lubrication The terms "detergem". "additive" and"com- of the engine during the critical warm-up period, thus pounded" used herein are intended to refer permitting flight wider ranges of climatic through to a class of aviation oils change without the necessity of changing oit Themulti- engine lubricating to which certain substances have been added viscosity grades are recommended for aircraft engines to improve them for aircraft use. These subjected to wide variations in ambient air tempera- terms do not refer to such materials com- n~es. particularly when cold starring of the engine monly known as "top cjrlinder lubricant", must be accomplished at temperatures of 300F. and be~- "dopes", carbon remover" which are some- low. The SAE Grades 20W-30, 40 and 50 shown on the times added to fuel or oil. Theseproducts charr are equivdlent to multi-viscosity grades of 65, 80 may cause damage to the engine and their and 100 respectively. It must not be presumed, how- presence in an engine will void the owner's ever. that multi-viscosity oils will alleviate all of the warranty. Under no circumstances should problems encountered in extremely cold enviromnents automotive oil be used. The use of automo- Ar these Cbelow +10DF.). temperatures preheating of tive lubricants in Lycoming engines is not the engine and on supply tank will be re~ired regard- recommended because its use could less of of on used. cause rhetype engine failure. ~LEVISED OCTOBER 1915 2-15 Island Enterprises SECTION POVVER PLANT Island Enterprises SECTIBN III POWER PLANT A. GENERAL The M20C and M20D are powered by a Lycoming 0-360-A1D, 180 hp engine. The standard M20D is equipped with a Lycoming 0-360-A2D, 180 hp engine, the 0-360-AlD engine being optional for a con- stant-speed propeller, Both engines have a compression ratio of 8.5:1 and require a minimum grade of 91/98 octane fuel. The M20E is ecpipped with a Lycoming 10-360-A1A, 200 hp engine having a constant-speed all-metal propeller. This engine must be serviced only with a fuel having a minimum grade of 100/130 octane. Two Bendix magnetos are furnished, the left magneto being ecluipped with a set of retard breaker points for a starter vibrator which furnishes long duration, boosted spark for starting. The ignition switch combines both starting and ignition functions. To supress radio static, shielded spark plugs and ignition harness is furnished as standard equipment. For derailed engine and propeller information, refer to manufacturers' handbooks, B, TROUBLE SHOOT~G Refer to the a_bpropriate Lycoming or Bendix manual for engine trouble shooting procedures. C, AIR FILTER CARE The incorDoration of an induction air filter in the engine air intake system significantly increases engine lifd. Dust panicles accumulate on the filter element and must be removed every 25 hours, or more frequently in dusty atmospheric conditions, to prevent obstruction of air intake during engine operation. To clean induction air filter (paper element): i. Removefilter from aircraft. 2. Direct a jet of air up and down the entire filter element lair nozzle must he kept at least 2 inches from filter). 3. Inspect filter for damage, holes, and presence of rec~uired gaskets before reinstalling. To clean air-maze toil) type filter: i. Removefilterfrom aircraft. 2. Washinsolvent. 3. Apply a light coating of lubricating oil. 4. Reinstall onaircraft. 2). ESGI~E REMOVAL NOTE: Experience has proven that it is much easier to remove and reinstall this engine with the mount attached to it. 1. Remove thepropeller 2. Removetheside cowls 3. Removethetop cowl 4. Removethebonom cowl 5. Disconnectthe following: a. ground cablefrombattery b. vacuumline c. landinglightwires (2) d. oilradiator.oil~ines.4bolts andclamps e. bracerods(connected tofirewall) f. cowl flap control rods REVISED NOVEMBER 1966 3-1 Island Enterprises g. cabin heat duct Cfrom elSoine) h. fuelventline i. tachometerdrive shaft j. oiitemperature bulb k. oilpressureline i. fuelpressureline m. manifold pressure line n. cylinder head temperature ~e thermocouple line 6. 3isconnectthefollowi~,o controls: a. throttle control b. propeller governor control c. mixture control d. cowlflap control and spring e. carburetor hot air control 7. Disconnect ignition switch wires from (Ground Magnetos) 8. Disconnect the engine ground strap 9. Disconnect allvoltage regulator wires 10. Disconnect 2 generator wires and 1 starter wire 11. Disconnect muffler, tailpipe, and support springs 12. Disconnect line from boost pump to engine fuel pump 13. Remove top engine baffle to expose hoisting hook and attach an "A" Frame type hoist or other suitable hoist to the e~cine hoisting hook and relieve the tension on the engine mount. 14. Disconnect four bolts from the engine mounts at firewall and slide engine forward slowly and carefully to check if any wires orcables are still connected to the elgine. (If it is desirable to remove the mount from the engine, it can be accomplished easier at this time). E. PROPELLERREMOVAL (CONSTANT SPEEDTYPE) 1. Remo7e propeller spinner (M20E F remove screws at forward bulkhead). 2. Remove 6 bolts and washers from propeller flange and gently remove propeller from the engine shaft. ~hen the propeller is removed from the engine crankshaft there will be a small amount of oilthat will run out of the propeller hub and crankshaft.) 3. Carefully remove the "0" Ring from the engine shaft. F. INSTALLATION OF ENGINE Reverse engine removal procedure. Allinstallations must be rechecked for proper torque and safetg- ing. Fuel and oil lines must be pressure checked. Engine mount torque val~res: Eng. Shock Mts.: 450 500 inch pounds; At Firewall: Top Bottom 50 70 inch pounds. G. INSTALLATION OF PROPELLER (CONSTANT SPEED TYPE) i. Install spinner adaptor ring to engine starter gear. 2. Clean engine shaft and propeller hub at flange. 3. Insert the "0" Ring into the groove located inside the flange mounting lubricating it libernllv with clean lubricating oil. 4. Line up the small "O" mark on the hub flange outer diameter with the short bushing in the cranlr- shaft flange. 5. Install propeller onto ego;ine shaft. Torque the 1/2 in. studs to 60-70 ft. Ib. Safety wire pairs of studs together. 6. Install spinner dome. H. ENGINE CONTROL ADJUSTMENTS Refer to appropriate Lycomine: manual for idle mixture, adjustment, etc. I. COWL FLAP OPENING ADJUSTMENT (See Figure 3-1) i. For M20C, adjust left cowlflap for 1. 1 in.-i-. 1 in. measured at the trailing edge when fully extended. 2. For M20D, adjust left cowlflap opening for 2.4 in.+.l in. measured at the trailing edge when fully extended. 3. For the 1964 1965 M20E, adjust left cowl flap opening for 2. 00 in. measured at the trailing edge when fully extended. For 1966 and subsequent M20E aircraft, adjust left cowlflap opening for 1. 65 in. measured at the trailing edge when fully extended. 4. For M20F, adjust left cowlflap opening for 1. 65 in. measured at the trailing edge when fully ex- tended. 3-2 REVISED JULY1980 Island Enterprises J. COWLFLAP RIGGING Rig right co~l flap to match left nap in up position. FIGURE 3-1 COWL FLAP OPE~ING AD~USTMENT C f~ C I C :-i~: -r i NOTE: All meosurements ore mode on left cowl flop only~ Rig right co\NI flap to motch left flop in ~p position. ·-i Island Enterprises SHOP NOTES 3-4 Island Enterprises SECTION STRUCTURE Island Enterprises SECTION IV SIRUCTURE A. GENERAL Figures 4-2, 4-3, and 4-4 identify skin materials used onMooneydircraft. Repairs such as skin in Aeronautics patching, welding, etc., may be made in accordance with the regulations given Civil the Manual 18. Skin repairs must result in a surface which is as strong as, or stronger than, original skin. However, flexibility must be retained so that the surrounding areas will not receive extra stress. B. REMOVALOFWING COMPONENTS The major subassemblies of the wing may be removed individually or the wing may be removed as a unit. To remove a wing, a fuselage supporting cradle is recpdred. i. Removal ofWing(Figure4-~) a. Remove wing root fairings, and the bottom fuselage access panels. b. Drain allgas fromthewing. c. Drainbrakelines andreservoir. I)isconnectatwingmainspar. d. Remove front and rear seats. Remove 2 inspection plates under rear seat area. e. Settheairplaneonjacks. (Usejackpoints as showninFigure2-l,) f. Set "A" frame on propeller. X· Remove the following: i. Twolandinggear assistsprings. 2. Disconnect flap hydraulic line at pump fitting. 3. Disconnect flap indicator housing in cabin. 4. Ailerontubes-two. 5. Disconnecttrimlinktube atstation59.3 andstation94.5. 6. Maingear retractiontubes. 7. Ruddertubes. 8. Elevatortube. 9. Elevator and rudder push-pull tubes-two. 10. Disconnect floorboard. 11. Disconnect seat rails. 12. Stringer assembly doublers- one each side 13. fourteenbolts fromshearplares. 14. Sixteen attachbolts-eight each side(ANB-M). REVISED NOVENBER 19~6 4-1 Island Enterprises 15. Bolts, nuts. and washers from front attach fittings on both sides. 16. Gas lines and wires from wing root. 17. Airspe~d indicator line. pitot lines, pitot heater wires if insta~ed. 18. Rear mating bolts (two AN4-I7A). 19. Two tension bolts (7H-16A). ~OTE: Have suitable cradle ready for fuselage before accomplishing last three steps of wing removal. 2. installation of the wing assembly is direct reversal of removal. SHOP NOTES REVISED NOVEMBER 1966 4-2 Island Enterprises m II1D9o -n IIIYI Uu.T I~R *IUIM IflP ·~tllM IHU1)KI I I I1IU( I I Illru I I atu I I grm G) ;o C )IOll(-P ;O I rn iSi I *HweclcL m I,lollc-l, I*sc-chl I I*awectrl 1 I I IAWlbJ-(11 I b VIEW LOOKIHC DOWH AN7H-)6A BOLT ~L, SMEAR PLATE L.H. SHOWN SEE ABOVE ttlART FOR HARDWARE C/O R.H.OPPOSITE m i Z m ANI DOLTS (SEE ABOVE CHART FOR LENGTHS IOGA SAFETY WIRE C) m 4 EACH SIDE USING RESPECTIVE SHIMS) ;o P FITTING I 71 o. C SHIM v, m AN3-4A BOLT r S~1EAR FITTING (REF.) AN363-1032 NUT \(8 EACH SIDE) AH96elOWASnER 'j (NUTS ACCESSIBLE 3: TI1ROUGH WI·1EELWELL] g Z AN363-428 NUTS (4) ACCESSIBLE C, THROUGH BOTTOM ACCESS PANEL rj (DOTTED) g C] ;D 5 SMEAR FITTING PLATE AN6-16A BOLT AN363-624 NUT AN960-616 WASHER (ONE EACH SIDE) AN4-15A BOLT (BOTTOM) NUT AND BOLT TORQUE VALuel EOY AN4-17A BOLT (fOP) SIZE (INCH- POUNDS)I ONE EACH SIDE AN960-416 WASHERS AN 3 12- 15 TWO EACH SIDE AN 4 30- 40 AN 6 1 95 110 1 ~AN7H-16A BOLT (SAFETY WIRED AS SHOWN ABOVE) AN960-716L WASHER AN 7 450 500 (BOLTS ACCESSIBLE THROUGH ACCESS PANELS ~J UNDER REAR SEAT AREA INSIDE CABIN) Island Enterprises FIGURE 4-2_ WING SKIN CHART igOh~i ~CI I -I -I I I I NO. THICKNESS Nt4TEEUAL t Z I 'I \9) 1· a·os9 2024 T-3 CI~9D Z 0.050 2024 T-4 CLAD I I~Lj h (3 5TA. 59.25 1 j 3. 0.040 2024 T-3 CLAD V 4. 0.032 2024 T3 O~AD i I ~--J----i I i 5. 0.025 2024 T3 CLAD 6. 0.032 (a) 2024 -O CLAD i 0.032 2024 -O CLAD 0.025 2024 r3 CLAD I I i (9) a 0.040 STA. )03.500 2024 T-3 CLAD ,,,C, 9. 0.025 2024 T3 CLAD f I 1 10. 0.020 (51 2024 T-3 CLAD i I 1 0.025 (e) 2024 T3 CLAD I I I v 11. 0.040 (9) 2024 T-3 CLAD i 12 0.032 2024 T~ CLAD I I I 1 ~3. 0.025 2024 T3 CLAD SSA. 347,750 r4. 0.020 (d) 2024 T-3 CLAD 15. 0.025 2024 T-3 CLAD 16. 0.020 (6) 2024 T3 CLAD 1~ 0.016 (6) 2024 T-3 CLAD 0.025 (e) 2024 T-3 CLAD 18. 8.025 2024 T3 CLAD STA. 193.500 (a) Neat Treated to T-42 condition after forming b) (51 9929 thicknur on bottom tide or flap. (c) Top ot wip~ only. ILIGHT WING SHOWING (d) Sune thicknas on both dde~ !e) Prior to 1965. 4-4 Island Enterprises FIGURE 4-3 TAIL SKIN CHART 7) (6) (4) (3) (2 i I 8 i' 9) 1 (9)1(10)(5)h0~ _L(9) 1 (9 12) (11)- 3~ (13 6) 1 ci~ 18 1 15 21: QP M20F M20C,D,&E NUMBER THICKNESS MATERIAL NUMBER THICKNESS MATERIAL 1. 0.040 (a) 20'4 -O CLAD 13· 0.040 (a) 2024 T-4 CLAD 2. 0.025 2024 T-3 CLAD 14· 0.025 2024 T-3 CLAD 3. 0.025 2024 T-3 CLAD 15. 0.025 2024 T-3 CLAD 4. 0.020 2024 T-3 CLAD 16· 0.012 (c) 2024 T-3 CLAD 5. 0.025 (b) 2024 T-3 CLAD 17· 0.012 (c) 3024 T-3 CLAD 6. 0.025 2024 T-3 CLAD 18· Mooney Extrusion -L;4142 '1. 0.025 202? T-3 CLAD 19· O.ozo 20241;-3 CLAD 8. 0.040 (a) -O CLAD 20· 0.012 (c) 2034 T-3 CLAD 9. 0.012 (c) 2024 T-3 CLAD 21· 0.0Zj 2014 T-3 CLAD 10. 0.012 (c) 2024 T-3 CLAD 22· 0.025 2024 T-3 CLAD 11. Mooney Exlrusion ,"1142 23. 0.020 2024 T-3 CLAD 12. 0.020 202~ T-3 CLAD 24- 0.040 3003 -0 (a) Heat Treated to T-$2 condition after forming. (b) Bottom 0.025 2023-0. H.T. to T~2 condition. (c) 0.016 may be used as alternate. REVISED NOVEMBER 1966 4-5 Island Enterprises FIGURE 4-4 FUSELAGE SKIN CHART 9) 41 (1 9)/(8 r'-7 1 I$ i 9U 91* rr* a* 111.11 Iri.oo 11.00 1(.00 19.60 0.00 MZOC,D&E 0 8 iii 165 B 5)(4) (1 9)/(2 1) 1 (14) (1)1 (8) (16`) 1 (15)(ii~ I (i~ (i arA aL\ --STA SU XA 99.10 111.11 llD.00 1(.00 51.00 11.11 0.00 M20F NUMBER THltKNESS MATERIAL 1. 0.025 2024 T-3 CLAD 2. 0.032 2024 T-3 CLAD 0.020 (6) 2024-T-3 CLAD 3. 0.032 2024 -0 (9) CLAD 4. 0.040 3003 -0 5. 0. 025 2024 -0 CLAD 6, (9) 0.025 (9) 2024 T-4 CLAD 0,025 2024 T-3 (d) CLAD 8. (9) 0.025 2024 T-3 CLAD 9.~ 0.020 2024 T-3 CLAD la (6) 0.020 2024 T-3 CLAD 11. 0.(n5 2024 -0 (9) CLAD 12. 0.025 2024 T-3 CLAD o.cno (8) 2024 T-3 CLAD 13. 0.032 2024 T-3 CLAD 14. (6) 0.032 2024 T-3 CLAD 15. 0.032 2024 T-4 CLAD 16. (f) 0.025 2024 T-3 CLAD NOTES (9) Heat Treat to T-42 (9) Right side only condition after forming (6) Leftsideonly (c) 0.032 can be used (9) prior to 1965 (d) 2024 T'-3 matetial on right side 4-6 REVISED NOVEMBER 1966 Island Enterprises SECTION LAN DING G EAR AN D BRAKE SYSTEM Island Enterprises SECIION V LANDING GEAR BRAKE SYSTEM A. GENERAL The landing gear is a tricycle gear type. It is constructed of~eavy, chrome-molydenum tubular ste~ heat treated for greater strength and resistance to wear. Neoorene rubber discs absorb the shoc8 of normal taxiing and landing. The attaching points of the main gear are in metal bushings embedded in the gear-mounting box and attached to the soars. The nose wheel is mounted to the cabin's tubular-steel frame. The main gear wheels are eciuipped with hydraulic brakes. B. REMOVALOF LANDINCCEARS i. MainGear, Retractable. a. Placeaircrzftonjacks. (RefertoFiguretl.) b. Unlock and move gear handle air a short distance. Disconnect the gear doors, brake lines, and the retraction tube. c. Retractgear alltheway. d. Remove the main gear retraction s~ring (see Figure 5-1). e. Extend gear to about 3 or i inches from down lock position and secure it or have someone hold it in this position. f Remove two bolts from retracting truss bracket. g. Remove six bolts from rear landing gear at attachment bracket, h. Slideout rearpartor bearng sideways. i Slide from part ofbearing aft and remove. i. Slide gear assembly aft slightly until clear of from bearing and carefully take out of wing. Main Gear- Fixed. Airer placing aircraft on jacks, remove fairing and linkNo. 510011-9. Repeat steps g through i in procedure above. 2. NoseGear, Rerraaable. a, Set aircraft on jacks (Refer to Figure 2-1). b. Remove exhaust cavities. c. Removebolronaftend ofretractingLink. 5-1 Island Enterprises UI Z! r: AN3-S BOLT AN3-12A BOLT c, c AN310-3 NUT fl rn AN380-2-2 PIN I CONNECTING LINK cn ~Le O IL_ I II F ;o I I I T?I ;o (I'i o V o zcn --y ----c-)-c- 3i- 1 Il.r I ~O RETRACTION SPRING z o MAIN SPAR 70 OLDING BLOCK _---- _ o ~AIN GEAR, RH Ec------8186 TOOL VIEW LOOKING FWD, AT RETRACTED RIGI1T HAND MAIN GEAR C! PROCEDURE FOR USING 8186 TOOL: o Remove the door. gear Remove the cotter Itey and nut at the spring connecting linh. Retract the gear and Insert a a"-thicle wood blocle to hold' tlie gear in the retracted position after detac!lment of the spring. in the attach Remove~ grease fitting gear bearing. Attach 8)86 tool forward of the connecting linle with on I\N3-12A bolt as shown the m In Illustration. Rotate the tool in an outboard direction using the upper trunion shaft of the gear fralne as a fulcrum. The linle attach bolt (AN3-5) can be withdrawn by hand when suf- ·o ficient leverage is applied to the tool. NOTE: Installation of the gear retraction spring Is die direct opposite of the removal procedure. Island Enterprises d. Partially retract nose gear by hand and remove bolt from nose gear steering horn. e. Bend flange of firewall to clear bolts of support truss. f. Remove right and left bolts of support truss. 8. Carefully removenosegear assembly. hTose Gear Fixed. Remove fairing and fixed links. Repeat steps "d" through "g" above. C. REhlOVAL AND DISASSEMBLY OF SHOCK DISCS (SEE FIGURES 5-2 AND 5-3) D. REASSEh·IBLY AND INSTALWTION OF LANDING GEAR Installation of the landing gear is essentially the reversal of removal. On reinstalling the main gear in the airdlane, be sure to keep parts from the right and left gear separated.. Do not attach gear door brackets to gear legs with sheet metal screws until doors are finally adjusted as explained in the fol- lowing procedure. i. MainGear. a. Grease wheel bearings, retraction linkage, and fare and aft bearings which attach to the spar (See Figure 2-9 for recommended lubricants). b. Slide front end of gear leg into front bearing; slide bearing plate of rear attachment over rear end of main gear leg, spotfaced side forward. c. Slide rear part of attachment bracket between spar and landing gear. d. Line up holes in rear attachment and spar. Attach with six bolts. e. Attach retracting truss through retracting bracket with two bolts and secure with safety wire. f. Connect retraction tube and fully retract gear. g. Connect,oearassistspring andlowergear. h. Attach gear door links to brackets on gear legs. Raise gear to see that there is no bind in door link bearings. Door edge should seat evenly against wing without excessive distor- tion where liriks attach to door. Adjustment may be made by slightly shifting the position of the gear door brackets on the gear leg or by changing the length of the links. This is a preliminary adjustment. Do not attach gear door brackets to gear leg with sheetmetal screws until door adjustment is rechecked after gear is rigged. 2. NoseGear. Installation of the nose gear is a direct reversal of the removal procedure. REVISED NOVEMBER 1966 5-3 Island Enterprises FIGURE 5-2 NOSE GEAR SHOCK DISC REPLACEMENT TOOL APPLICATION DATUkLLINE (STA. O.OQ) BELLY SKIN LINE COLLAR BOLT HOQK TOOLHO.ME120 SCPEW_ j j i shown. Two PROCEDURE FOR USING TOOL: Remove wheel and spindle. Attach tool os pins (chained screw clockwise vntil tension on collar to tool) ore placed in geor Ieg bolt holes. Torn compression discs it relieved. Remove collar bolt and collar, Relieve tension on shock by tuming compression be removed. screw Shock discs may then NOTE: Geor doers need not be removed. 5-4 Island Enterprises FIGURE 5-3 MAIN GEAR SHOCK DISC REPLACEMENT TOOL APPLICATION SPINDLE ··...;·····..I·: .X: i3` .r.r.l.·.·.· ~j ·r·-···.·.·. '"'·:2~. .;~-:y. ·_····~····-···-·· t·-:·:··-?.-.·.~::;._,, ··.·.·.·;·;i·-·.·'··. I-- ··.r ii···.···· -.Ti·(·-·. ·-····r·-··. c· ·'··-:·X·-:I· -·;.·.·;2;·:·~·:·.-: CMIPREIIIO*SCREa ;TZ·· TOOL NO, ME121 2~I· j ·-·-i·-i· -.····...i :·:·:·:·:·i::::·:':'·· ;:::::::::.:i:jj:;.;·1:;.·...·.. ~:2:j;i::·: rr I i :ij PROCEDURE FOR USING TOOL: Remove spindle attach bolt at shock disc guide, swing wheel forward and ottach tool os shown. Turn compression tool clockwise until collar bolt on collar is aligned with access hole. Remove collar bolt through access hole and relieve tension on shock discs by turning compression screw counterclockwise. Shock discs may then be removed. NOTE: Gear doors need not be removed. 5-5 Island Enterprises 3. Instructionsfor ri~,oingnosegeardoors. a. Raise airplane off of ground by method described in Section n-C-I. b. Connect gear door links to gear doors (upper holeinbracket). Gear retracrionsystem must be rigged before gear doors can be rigged properly. c. Gear doors must be timed td open and close correctly without contactingthe gear. On 1962-1964 models, timing is accomplished by adjusting a screw on the cam. Turning the screw clockwise speeds closing. Turning the screw counterclockw;se slows closing. d. M-20C E Models (1965 gr OrJ) incorporate door retraction arms on the nose gear retrac- tion truss. To rig nose gear doors, adjust links shown in Figure 5-4. e. Doors must be checked for a tight fit when in c~e closed position. Play may be taken up by adjusting the gear door links. f. If the gear, in the retracted position, prevents the doors from closing completely, the ec- centrics on the retract truss must be reset to raise the gear in the wheel well. The same applies for lowering if the gear is retracted too high in the wheel well. NOTE: if item "f' is incorporated, items "c" and "e" must be repeated. E. BRAKE ANDWHEELMAINTENANCE i. Braltelininginspectionand replacement (FigureS-5). Visually inspect the brake while it is insta~ed on the airplane. No adjustment of brake clear- ance is necessary. If, after extended service, the brake linings become excessively worn, re- place with new linings as follows: a. Removedustcover fromwtieel. b. Remove spindle nut from one side of wheel and two bolts from the other side (2 bolts that hold back brake plate stationzry). c. Slide wheel out and remove pressure plate that has the worn lining on it. d. The linings can easily be replaced by drilling out three rivets from thepressureplate and three rivets from the back plate. e. old Replace linings with the new Cleveland brake linings and Cleveland 561 rivets. A 561-R rivet kit is available setting through your local Mooney distributor. This special rivet set- kit should be ting used, as rolling of the rivet is very important to get atight fit between the rivet and the rivet hole. REVISED NOVEMBER 19Lb 5-6 Island Enterprises ·,p I 5t IkrWC~y 71 r t: o c :I!n ··I'I`UB~f ;a rn I·I r*! Cn d ------·-n...,·-- ·n;~ (L J i ly~) ~flB, V *I·I i ~i Z r4 Q 411:l~f n" v, rr rn i i1,, a I c, ··1~ ·''~i· m r,· NOSE GEAR 1 irl i O S;L RETR4CflON TRUSS O ·Il)"tr' ;O ECCENTRIC ·r i BUSHING AMD X1 ~C4Y. 4: HARDWARE r_qog~ NOSE GEAR C, 2 PLACES. LINKS AND.CLOSING C, .s ADJUSTMENT Z 2 PLACES G) 'I\ .IY tl O 70 ·9·I·r·~ '4· ~1. Island Enterprises SHOP NOTES 5-s Island Enterprises FIGURE 5-5 BRAKE CYLINDER ASSEMBLY PRESSURE PLATE ASSEMBLY LINING RIVET PLATE PRESSURE BACK PLATE ASSEMBL LINING RIVET 3 PLATE BACK CYLINDER O-RING PISTON BUSHING BLEEDER SCREW BLEEDER CAP BLEEDER 5-9 REVISED NOVEMBER 1966 Island Enterprises FIGURE 5-6 WHEEL ASSEMBLY CHART 2 5---8 6~--s 4 1. DUSTSHIELD 2. SCREW 4--~ 3. LOCKWASHEt( 4. HUBCAP 5. SCREW 6. LOCKWASHER 7. TIMKEN BEARING CONE 8. TIMKEN BEARING CUP 9. SPLINE-NUT(ESNA) 10. OUTER WHEEL HALF WITH BEARING CUP AND SPLINE-NUTS. 11. INNER WHEEL HALF WITH BEARING CUP 12. THROUGH BOLTS P~S 14 13. WASHER 15 14. GREASE SEALRING 15. BRAKEDISC ASSEMBLY 16. GREASESEAL FELTWASHER 17. WNERDUST SHIELD 13--9 ~--1S 12- 17 5 5- 10 REVISED NOVEMBER 19ib Island Enterprises TI O c: 70 m cn 3: ;a "O" RING AN-6227-10 r AN-6227-9 '~O" RING m 70 00 r r v, 00 70 n AN-6227-3 "Q" RING AN-6227-5 "O" RINt; (REPLACED OHLY WITH NEW A-1/7G-045 VALVE) 00 70 v, v, m r MODEL V-l m r Island Enterprises FIGURE 5-8 PARKING BRAKE VALVE ASSEMBLY CLOSED OPEN 4207 GASKET O X AN62n-5 "O" RING AN6227-1 "O" RING 5-12 Island Enterprises FIGURE 5-9 PARKING BRAKE VALVE ASSEMBLY (AI;TERNATE) 3*T 5~21- MODEL 4500-A1 USED a AS ALTERNATE FOR I" 4200A1. PAR'TS LIST O So. Port h·o. Usfd On Nama N.Raq' L500 1 I ~9 I 4501-2 L500-XI Body 1 4500-~2 Modal 4500 4500C 1 4500-1 BOdy I 4500C-~I 45005 1 4501 45005-;\1 8cdy 1 45005-A2 4504 bun k~embly 4505 Stem Induded in 2 4506-1 VolveHeod A~unblyNo. 4507 Spnns 4504 19649 Spn'ng Pin 6500 1 POSITION 2 3 4511-2 :500-~1 SM· '"Ive 1 4500-;\2 l--i FULCa'JM 1 I 4500C 3 14511-1 See' "--le 1 4500C-X1 PORT B 45005 I I I V? 3 4511 45005-A1 San' \'-lve 1 4500S-A2 I I I nrJ OHVI 23' 18048 0-Ring 3/4" O.D. x 9/16" I.D. 1 PORfA rPtl 1 1_131 5 1 18033 O-Bing 3/8" O.D. x 1/4" I.D. 1 6 4503 Spocer (used with Ann Pos. r) 1 I ~O 6 4503-1 Spccer lured with Arm Per. 2) t 7 4208 Ann Auembty 1 POSITION I 8 18286 River 3/32" x 5/8" it H. 5:eal 2 9 4222 WDJhH 3Urr, Steel 4 1: a4 5 7~ O 5-13 Island Enterprises ·Z! k RETRACTINGTRUSS ~X.4`r 2 10 m RETRAC'TING LINK ---t r 3/16" OVER CENTER n DETAIL OYERCEHTER LINKAGE so 1(1 C) Z G) t3 MAIH GEAR ADJUSTMENT 8 NOSE OEAR ADJUSTMENT 8\ m I c m cl a REMOVf THES~ m BELLY ACCESS PANELS r ra m O ;o Island Enterprises 2. BrakeBleeding. When braking action becomes spongy and erratic or when repairs require the replacement of actuating components, it will be necessary to bleed che hydraulic brake system. Sest results are achieved with the use of a hydraulic fluid system bleeder (pressure poi) pressurized with air to approximately 35-40 Ibs. When bleeding dual brake systems, both the pilot's and co- pilot's brakes must he depressed alternately during bleeding to reposition the shuttle valves. First, remove the vent cap from atop the firewall fluid re~ervoir and attach a fitting and hose that will carry expelled fluid from the reservoir to a clean catch pan positioned next to the hose section. Remove the rubber cap at one of the main wheel brake cylinder assemblies, open the valve by backing off the small center pin, and attach -~e pressure pot hose. Air bubbles in the fluid being expelled from the reservoir will give the stream a milky appearance. When the fluid Nos clear and transparent into catch pan, close the bleed valve, disconnect the pressure pot hose, and cap the bleed valve. Repeat the procedure with the other side of the system, After disconnecting the overflow tube from the reservoir, remove excess fluid from the reservoir through its side plug to re-establish the proper fluid level. 3. Wheel Assembly Inspection. a. Placeairplaneonjacks (SeeFigureZ-l). b. Remove axle nut and two bolts from back plate and slide the wheel off. c. Check for bolt failure. Replace any bolts found to be defective (Figure 5-6). d. Check the internal diameter of the felt grease seals. Replace the:elt grease seal if surface is hard or gritty. e. Inspect the casting for visible signs of cracks or corrosion. If there are any indications of cracks, the tire and tube should be removed and the wheel disassembled for a closer in- spection. f. Replace any wheel casting having visible cracks. F. MANUALLANDING GEARRIGGINGPROCEDURE The ~ar retraction system is designed to hold the gear down-and-locked only when the retraction linkage is in the overcenter configuration. Collapse of the gear, at landing or during taxiing, due to a disengagement of the locking mechanism, can be caused by improper adjustment of the overcenter lock mechanism or by disengagement of the retraction handle from its down-lock block under the instrument panel. 1. Rigging Instructions. a. Raise airplane and remove access panels shown in Figure 5-10. b. Remove retraction handle from gear-down lock. Tiehandle loosely to prevent bungee from forcing it down. In order to prevent damage to retraction tubes, do not move gear legs Trom outside until step C has been accomplished, c. Disconnect retraction tubes at point B (Figure 5-10). Loosen hearing, check nuts on tubes at point E and on tubes at point A. d. Check nose gear and main gears (2) for any binding at hinge points (Figure 5-10) while mov- ing gear legs back and forth by hand. Tubes may be disconnected at point C during checle of main gear. Lubricate gear retraction system at points indicated in Figure 2-9. e. Place the retractionhandle inrhe gear-down lock. Check for and remove any foreign matter lodged between the retraction truss and retraction link connection at points Z Sas shown in Figure 5-11. Place all gears in the down-and-locked position. it is recommended th,7t C-clamps be attached at points X R (Figure 5-11) to hold the retraction truss firmly in the overcenter configuration. REVISED OCTOBER 1972 5-15 Island Enterprises f. By turning tubes, adjust retraction tubes so that a 3/16" OD bolt can be inserted through re- traction lever and bearings at point B (Figure 5-10). This will give a zero preload in the system wit~ the handle in the gear-down lock. g. By turning tubes, shorten retraction tubes two turns and lenghen retraction tubes two to two and one-half turns. Tighten check nuts (4) at points A and E (Figure 5-10). h. Remove retraction handle from gear-down lock positipll and connect tubes. Replace retrac- tion handle in gear-down lock position. i. Inspectionof System Preload. a, Nosegear (seeFigureS-ll). 1. Place rigging tool (8442) on retraction link with sloped edge aft. Hold tool inplace against retraction link. 2, Placefinger atpointR. 3. Apply force on torcF~e wrench and read torque at the instant point R first begins to move. Movement of retraction truss may be felt at point R and may be seen in area of ~oint S. Practice this several times before recording torque. should be between 100 and 130 inch pounds. NOTE: Take reading on torque wrench when .005 to .010 inch movement is observed at points R and X (Figure 5-11). 4. After release of force, retraction truss should snap back to full overcenter and should bear tightly against retraction link at point S, This should be carefully checked by pulling down on retraction truss. If retraction truss moves down, then the preload in tubes is not sufficient. 5. Eccentric bushings at point A on the nose gear retracting truss may be rotated as re- cluired to obtain the proper gear-up travel and proper gear door rigging. CAUTION: Nose gear dowrlock rigging must be rechecked after eccentric bushings are changed. b. Main Gear (see Figure 5-11). 1. Place rigging tool (8444) as shown in Figure 5-11. Hold in place with thumb at point Y pressing forward. 2. Placefinger atpointX. 3. Apply force on torcpe wrench and read tor~e at instant that point X first begins to move. Movement of retracting truss may be felt at point X and may be seen in area of point 2, Practice this several times before recording tor~e. Tor~e should be between 240 and 280 inch pounds. The difference in left and right gear tor~e should register within t25 inch pounds of each other. 4. After release of force, retracting truss should snap hack to full overcenter and should bear tightly against retracting link at poirit Z. This should be carefully checked by pulling down on retracting truss. If retracting truss moves down, the preload in tubes is not sufficient. CAUTOOT: Do not attempt to rig the gear to increase or decrease gear-up travel. 5-16 REVISED OCTOBER 1972 Island Enterprises 3. ~djustmenr ofPreload. If the torque values do not fall within the limits specified, then the system preload should be chan~Sed by changing the lenghs of retraction tubes. This is done by taking a turn on the rod end bearings in theprsper direction. One-half turn is usually sufficient. Any adjustment made to the nose gear should be made identically to both retraction tubes since they should carry the szme~reload. Since the retraction rubes from all gears are attached to the gear retraction lever. a change in preload in the retraction tube at one gear can affect the preload in the retraction tubes at the remaining gears. Therefore, after an adjustment is made at one gear. the other gears must be rechecked. This process must continue until the proper preloads are obtained in the retraction tubes at all gears. The amount of freedom of the gears las determined from the check made under item 4 of rigging instructions above) will affect the torque readings. Gear systems with free joints will be ade- quately rigged when the torque is on the low end of the range while the gears that are stiffer may require torque values on the high end of the range for adequate preload. A final check should be made of the force required to place the gear handle in the gear-down lock (,oear extended position). If the force re~uired to move thegear handle forward the last one to two inches is escesshe, then the system prelozd may be reduced slightly within the prescribed torque limits. Check for and relieve any bind in the sliding hand grip at the top of the gear lever since a bind at this point may make it difficult to lock the gear handle in place. SOTE: Gear rigging tools (8442, 8444, 8186) may bepurchased at a nominal cost through the ~iooney dealer and distributor organization. SHOP NOTES 5-17 RGVISED iUAY 1919 Island Enterprises FIGURE 5-11 TORQUE WKtNLn I IUN UIA~KAM Retraction Tube Main Gear 1 L·s J I i, a y Retraction Truss .f 9~·--, Retrclcrion Link r-7 RiggingTool L,~ (8444) Torque MAIN GEAR Wrench (VIEW LOOKING AFT FROM FRONT OF RIGHT GEAR) force Retraction Truss O i. L* iFZ ~L f~. ~f- S Retraction Upper Gear Link P·-~9 Structure I~ ~i F. i ar .1 ii 'i, 1. Rigging Tool (8442! Torque Wrench NOSE GEAR !VIE\Y LOCKING IN FROM RIGHT HAND SIDE OF NOSE GEAR) 5-19 REVISED NOVEMBER 1966 Island Enterprises G. INSPECTIONOF WNDINGGEARSHOCK 1. RubberDiscs. If a landing gear shock unit fails to pass the inspection described in Figure 5-12 5-13, t~e rubber shock discs must be replaced. NOTE: A check of the nose gear shock unit can also be accomplished by checking the propeller clearance as follows: With the unloaded aircraft on a flat surface and the tires inflated to the proper pressure, a 74-inch propeller should have a minimum of 9 I/2 inches clearance from the ground. Less clearance may indicate that the rubber discs are r'.e- fective and that a more thorough check should be made. 2. Collars andBolts. a. Inspect landing gear shock absorber bolts and collare(See Figs. 5-12 5-13) for deformation or indications of failure. b. Remove collars and bolts at each annual inspection and check for bends, wear, and cracks. Replace if necessary. it is suggested that s_Dare pans be obtained prior to this inspection. I)o not replace a bolt without replacing the collar, or a collar without replacing the bolt. c. See Figures 5-2 and 5-3 for removal of shock discs and collar. 3. Nose Gear Snubber. A hydraulic shock absorber is installed on the nose gear of 1966 O?! ~IZOC,E,&F models. The shock absorber housing is sealed and the unit requires no maintenance. When worn to a degree that effectiveness is impaired, the entire unit should be replaced. 5-20 REVISED NOVEMBER 1966 Island Enterprises FIGURE 5-12 LANDING GEAR SHOCK DISC INSPECTION DIAGRAM 1962-'65 M20C INSTALLATION 1963 g ON M20D INSTALLATION (WITH CONSTANT-SPEED PROPELLER) 1964-'65 M20E INSTALLATION COLLAR MAIN GEAR: With the aircraft at static weight, the gap between th~ main gear collar and plate Ut 1 should be 0.00 to 0.13 inches BOLT, h c;,l~n ~Mox. clearance of 1/8 inch:~ NOSE GEAR: With the aircraft at static weight, there must be no gap between the nose gear collar 'PLATE and plate. EIOTE: Static weight full fuel, less SHOCK UNIT passengers. O O WHEEL 5-21 REVISED NOVEMBER 1966 Island Enterprises FIGIIRE 5-13 LANDING GEAR SHOCK DISC INSPECTION DIAGRAM 1966 B ON M20C. E d F INSTALLATION (ALSO LORD DISC RETROFIT INSTALLATION) AN6-15A BOLT E~41N GEAR: AN960-616 WASHER There should be no gap AN960-616 WASHER between the collar and AN363-624 NUT upper retclining plate LLAR when inspected with the aircraft on lacks. The preload in the rubber discs must be great to maintain a enough PLATE complete extension of the wheel during re- traction. Understatic weight, a gap Is permiss- SHD ibie (0.00 to 0.43 in. ~7/16 inl). E NOSE GEAR: I /O Under static weight, there should be no gap between GUIDE the collar and upper 'e' i ~3Y 1 PIN ASSY. taining plate. NOTE: Static weisht= full fuel, less passengers. AN6-13A BOLT WASHER (2)I AN960-616L WAS HER AN363-624 NUT 5-22 REVISED NOVEMBER 196~ Island Enterprises H. ELECTRIC GEAR SYSTEM (OPTIONAL) I. Operation. T;ia gear retraction system is by the wheel-shaped switch knob on the upper portion of the flight panel. To raise the gear, the knob is pulled out and moved up to its upper detent. An "air switch" is incorporated in the electrical circuit which prevents landing gear retraction until a safe airspeed is ~ittained (See NOTE). The action of the system may be monitored visually by watching the movement of the indicator mark through the glass in the floorboard aft of the nose wheel well. A limit switch will stop the gear in its retracted position. To lower the landing gear, the is pulled out, moved down, and placed in the lower detent. A limit switch will stop the gear extension when the proper locking force has been exerted to hold the gear down. There are three ways to check that the gear is com- pletely down and locked: a. The green "safe-to-land" indicator light ton the left ~nel) will come on. b. The black indicator marks, as deen through the glass in the floorboard, will be aligned. c. No audible warning horn sound willbe heard when the throttle is retarded. NOTE: An 80 mph air pressure equivalent must be applied to the pitot tube orifice to actuate the airspeed pressure switch which permits retraction of the gear. Attach a 12-inch length of 3/8-inch rubber hose (surgicaltubing) over the pitot tube end and pinch the open end of the hose with a cotter pin. Rotate the cotter pin until the compressed air in the hose activates the air switch. 2. Manual Operation of the Electric Landing Gear System. a. Pull landing gear circuit breaker OFF. b. Put pear switch in the gear-down position. c~ Push crank engage handle forward. d. Crank clockwise approximately fifty (50) turns to lower the gear. e. Gear is down when green gear light is on-check gear position visual indication. CAUTION: Do not retract gear with the manual handcrank. Use electrical retraction. 3. Electric Gear Inspection. At each 100 hours of service, the electric gear system pivot points should be lubricated (See Figure 2-9) and test run with the aircraft on jacks (See Figure 2-1). Check the landing gear actuator for security of mounting, cleanliness, and indication of overheating or damage. Lubri- cate actuator ball screw with recommended lubricant every 100 hours. a. After 500 hours of operation and each 200 hours thereafter: (1) Remove the actuator from the aircraft. (2) Remove the end cap and wipe excess grease from gears. (3) Visually inspect gears for wear as follows: With open end of actuator toward you, rotate jack screw shaft counter clockwise to remove all slack from ring and worm gears. ~Iake an index mark on one gear tooth and on the inside of housing. Turn jack screw shaft clockwise until ring gear contacts worm gear and check index marks. Visible wear or backlash of 1/2 tooth or more requires immediate replacement of gears. ALTERNATE PROCEDURE: Measure backlash by using a .025" diameter wire or .025" thick shim as a feeler gage. If feeler can be inserted between gear teeth replace gears. Repeat above prccedure after rotating the ring gear thru 900; Ie0O; and.2;00: Repack gear box with recommended lubricant. ~5) Reinstall end cap and resafety. (6) Reattach helm bearing to bellcrank (refer to page 5-24 Section 5, paragraph B for proper actuator adjustment and reinstallation instructions). d. Perform retraction test through at least two trouble-free cycles. Check for: Proper limit switch adjustments. Position indicator adjustment and operation. Excessive friction or binding. Nose and main gear rigging. Main and nose gear door-to-jamb rigging. REVISED OCTOBER 1975 5-23 Island Enterprises 5. Electric Gear Rigging Procedure. a. Jack aircraft (See Figure 2-1) and remove access panel (See Figure 5-10). b. Disconnect all retraction tubes and the actuator helm end from the retraction bellcrank. Check the 7.50 actuator dimension (See Figure 5-14, Item 1). Adjust helm end as neces- sary to obtain the 7.50 dimension. Position the ball returns on the actuator barrel so that they face the actuator motor, then reinstall helm end on to the bellcrank. NOTE: When installing helm bearing end in the bellcrank, position it freely so there will be no lateral bind on the jack screw. Place one AN960-716L washer next to the ball joint, (can be placed on either side) and shimremaining space with AN960-616 washers. This installation will prevent helm bearing from twisting too far, yet provide adequate movement. NOTE: Previous installation may have contained one large AN960-916 washer next to the balljoint. This washer must not be reinstalled, the AN960-716L smaller and thinner washer described above is used as a replacement. c. Rotate the emergency gear extension handcrank to obtain the 1.56 dimension (See Figure 5-14). Adjust the retraction tubes so they can be slipped in place with zero preload. d. The bell crank is now in the gear down-and-locked position (green light on). Now adjust main gear retraction tubes so that the main gear rigging torque is between 240 and 280 inch pounds (refer to figure 5-11). The difference in left and right gear torque should register within 25 inch pounds of each other. Adjust nose gear retraction bungees so that they have a deflection of 0. 060 inch in the down-and-locked position (Refer to paragraph VF2 and figure 5-14, items 2 and 3). e. Position limit switch striker arm so that the gear-down light switch has just closed (green light on); secure the striker arm in this position. The gear is now rigged for the gear- down position with allowance for overrun of the actuator after cutoff. f. With all gear doors disconnected, run the gear up until the main gear is 0. 13 inch from the bumper pad. Position the gear-up limit switch striker arm so that the switch has just closed, then secure the striker arm in this position. The red gear-up light is now on and the gear is properly rigged in the gear-up position. g. Extend gear to down-and-locked position. Adjust gear door linkage (Refer to paragraph VD Ih VD 3 for door rigging instructions). Cycle the retraction system through at least two trouble-free test operations. Manually extend gear and recheck nose and main gear pre- load for limits specified inparagraph d. above. The gear is now properly rigged and ready for use. ITEMI FUS STA 33.0 ,.,,i BALL NUT BELLCRANK 7.50 .125 -I 1.56 ITEMB GEAR ITEMS BUNGEE NOSE GEAR BUNG~E L I .060 --1~-- .060 DEFLECTION OF SPRING FROM STATIC TO RIGGED POSITION FOR 1965 1962, '63, '64 MSTALLATIONS ONINSTALLATIONS Figure 5-14 5-24 REVISED OCTOBER 1975 Island Enterprises FIGURE 5-15 SAFETY SWITCH g EMERGENCY GEAR CRANK INSTALLATION F. S. 19~5 eRKT. AEj742-8 CLAMP (Taps end Shellack Tube Under Clomp) i AN3-3A AN960-10 i AN365-1032 2 PLACES i FUSELAGE TUBULAR STRUCTURE SKIN 1MPERIAL272P ~EE1/4x1/8 AN526-63254 LINE AN960-6 2 PLACES PRESSURE SWITCH SAFETY SWITCH DRIVE CONNECTOR CABLE ASSEMBLY EMERGENCY CRANK 3 ol/Xi~ CIRCUIT BR CIRCUIT BREAKER (ONLY`1966 g ON) 1 /5~ MSZ1919DG18 MSZ1919DG6 AN3-5A AN960-10 ADEL 750-8 CLA~P AN365-1032 ANS26-832R8 (2) 2 PLACES AN960-8 f2) NN365-832 (2) AN526-1032R6 AN960-10 4 PLACES ARENS 141 NUT(4) XN970-3 (2) CABLE HOUSING REVISED NOYEMBER 1966 5-25 Island Enterprises 71 rn AN'J-S~ C) hN960-10 C m AN365-1032 AN960-516L jtl 2 PLACES UOTI( SIDES OF BALL 71 cn MICHO SWITCII hN3-7h (2) SWITC~I ACTUATOR AN36J-1032 (2) OI 2PLhCeS Fl m COVER ~J; ;O AN4-22A WINDOW *I~sao-nla c~ AN365-121E\ CAL t) AN3-12A *NPb0-IO p AN965-1032 jO 2 PLACES ~N3-IOA ANPb0110 AH365-1032 VAH3-13A(2) i13 nN96a-I012b)AN363-IOjZ n -i .··J DUKES DRIVE Z CONNECTOR v, AN536-10j2R4 V, AN960-10(3~ -1 ~N365-1032 71 2PLACES DECAL Z GELL CRANK V, AN)-IIA -S AN960-10(5) AN365-I 032 DUKES ACTUATOR I~ I~ ;i) AN060-016 m AN4-2IA hN6-14A AN060-416 AN060-616(4) O AN365-42D ~C AN365-1?4 liv Z Island Enterprises YELLOW 71 RED r/L~ m j, -3 -35~ CC) ELECTRIC FUEL PUPP ;D CIRCUIT DHEAKER ACTUATORLANUI~IG GEAR m r uc ~1-1 U m -5 GEAR WAR)(I)(C L. rn BL clCK llOR1( m r m -Z I- X -·ir I n (h I/ss 00YIH ~O neLAY n -17 38 u,-J--: -15· c, m GEAII WX, DUSS SWITCII CIRCUIT OREAKER L~P ;o -11 j i '/ss I --I~ I I I I DN Z up RCLAY -7 1 I "t I I I I I I x, n =r -/9 TIIROTTLE m -9 SWITCII -23 C POWER BOOST DOOR SWITCI1 (MZOE) UP LIMIT IWITCII xr n ~t---'3Q0\ NC SAFETY SWITCH 1 I I Ln v DOWII LIMIT YWITCII 1 -3/ =198 ~-29 -s· --29 -27 I; '33----1 NOTE: ALL DASH NUMBERS ASSOCIATED WITI1 AN POWER BOOST DOORI ASTERISK ARE PRECEDED GEAR DOWN LIGIIT 9 WARNING L IGHT F BY TtlE NUMBER 800007 ~;r·9 NUMBERS '3b (M20E1 ALL OTHER DASI1 ~I ARE PRECEDED BY I: L 950090 -C41 NUMBER -.I 23 ·92 GEAR UP LIGIIT Island Enterprises YELLoW ry\ D >------3 AUX. BUSS OJIR LANDING GEAR -51 71 IL~ ACTU~TOR 1 tx, o c ;o m Ln s PO "I I I 1 -5'0 1 RELIAY -15 r GEAR mm SWITCH n -II u, 03 70 n AUX, BUSS OAR C) UP CIRCUIT DREAKER RELAY -II m;a5~ 70 -21 YWPITL Z O rto -23 u, 39 I I I I I n =0 SAFETY 1 SWITCH POWER DOOST DOOR "I -31 SWITCH (MZOE) -25 --I 61 eL, DOWN LIMIT SWITCII -29 -61 JC-13 NI o\ -"53 z IL t 5( 1 IP Yljl 65 -----nalGEAR DOWN LIGHT 1 Y m -21 30 I I o (I pnWcg tOOST DOO11 z o ajl 12 WARIvIlJG LIGHT (M20E) SC)IEMATIC S~IOWN WITH GEAR DOWN 8 LOCKED, TI1ROTTLE I CLOSED, ZERO AIR SPEED, GEAR UP LIGHT m AND FILTERED hlR ON ~o 65------ THROTTLE SWITCH GEAR WARNING HORN Island Enterprises 71 r: G, C ~n nED m YELLOW rn '2 GEAR SWITCI1 V1 O AIR PRESSURE SdFETY SWITWI ACTUATOR q; `O m s~7 I I I I L 01 2 m m ;0 90 r as p m n 1 ;O T)1ROTTLE GEAR I I I n WARNING SWlfCH AUX, OUS GEAR WARNING )IORN O ancul~roAR o ~1111 11 i onEnHER ;Dm Y 1\PP 1(1 22 ZP ;o Z O v, n 1 rn r ON LIMIT SWrrcH UP LIMIT SWITCH -1 POWER BOOST SWITCH \MZOELF) t n POWER ROOST c, h, LIGHT I x \O ·1 No I~I/-----' J~hl-, I III( A (M20EBFI OI IP 34 85 O Z v GEAR Y2 DOWN /-1~II. OEARUP LIGHT \~JI11' LIGHT GREEN ~T RED IO 14 cn Island Enterprises SHOP NOTES 5-j0 Island Enterprises SECTION CONTROL SYSTEIVIS Island Enterprises SECTION VI CONTROL SYSTEMS A. The ailerons, flaps elevators, and rudder are of all-metal construction. They are jig-built, using hinges of machined e?L~rusions. The elevator and rudder incorporate an unusual method of construc- tion. The leading-edge spar of these controls consists of a specially designed extrusion that allows flush attachment of the skin. Lead counterweights are provided for dynamic balancing to prevent flutter. Push-pulltubes, rather than the conventional cable system, are used to actuate the controls. Rod end bearings are used throughout the control system. These bearings are simple and dependable and require very little maintenance. B. fiE~VjOVAL ANDINSTALWTION I. fiemowl and Installation of Aileron. a. Remove controltube attachment from inboard end of aileron. b. Remove bells, nuts, washers from three attach hinges. c. Remove aileron by pulling straight back. d. Replacement is accomplished by reversing the above steps. e~ Rig the ailerons in accordance with rigging instructions. 2. Removal and Installation of Rudder. a, Remove the rudder controltube attachment by taking off one bolt, nut and washer. b. Remove bolts, nuts and washers from three attaching hinges. c. Remove the rudder by pulli~ straight back. d. Replacement is accomplished by reversing the above steps. e. Rig the rudder in accordance with rigging instrucitons. 3. Removal and Installation of Elevators. a, Remove control tube and assist bungee attachments by taking off all attaching bolts, nuts and washers on each elevator. b. Remove bolts, nuts and washers from four attaching hinges on each elevator. c. Remove elevator by pulling straight back. d. Replacement is accomplished by reversing above steps. e. Rig the elevators in accordance with rigging instructions. 4. ilemovalandInstallationof Flaps.~ a. fieomve ai~a-flap hinge fairing to expose flap link. b. Remove flap link attachment by taking off one bolt, nut, and washer from flap attachment. c. Remove hinge bolts. d. Remove flap by pullipP down and out. e. Replacement is accomplished by reversing above steps. f. Rig the flaps in accordance with the rigging instructidns. 5. fiemovaland Installation of Empennage. a. Remove fairing from both sides of tailcone at empennage attaching point. b. Remove access panels from aft tail cone as needed to accomplish empennage removal. c. Disconnect electrical and antenna connectors and clear through bulkheads as needed. d. Remove elevator and rudder control attachments from aft side of bell cranks. e. Remove trim jack screw fitting from empennage fitting by taking off bolt, washers and nut. f. Remove hinge pin from lower hinge assy after removing cotter pin from one end of pin. g. Remove bells, washers and nuts from upper hinge brackets, one on each side of empennage bulkhead while keeping weight of empennage neutralized by a cradle or man power. h. Set empennage in cradle until ready for replacing. i. Replacement is the reverse of the above steps.. CAUTION: Be certain the elevator and rudder rod ends are properly lomted when attachment bolts, washers and nuts are installed through bellcranks. j. Rig trim system, elevator and rudder in accordance 'with rigging instructions. dFI)TCCT\ n.T~V 1979 Island Enterprises 6-1 FIGURE 6-1 CONTROL SURFACE BALANCING DIAGRAM HINGE LINE (Refer to parograph C. below for dimensions oml limits) UNBALANCE FORCE C1 CONTROL SURFACE BALANCI~fG CAUTION: When repairing or repainting the control surfaces, the following limits must not be exceeded. Ailerons: M20D, SIN 101 thru 260, P/N 230000. M20C, S/N 1940 thru 2741, 2743 thru 2806. M20E, S/N 10lthru 399, 401thru 469. Maximum allowable static unbalance force: 9. 6 inch/pounds 753 pounds or 12.00 ounces) at 12.75 inches aft of hinge line. Balance weights: P/N 230009 1 2. M20C, S'N 2742, 2807 thru 3466, MiOE, S/N 400, 470-1308, P/N 230015-1 -2. Mavimum allowable static unbalance force: 7. 282 inch/pounds 57 pounds or 9. 1 ounces) at 12. 80 inches aft of hinge line. Balance weights: P/N 230016 1 -2. M20C E, S/N 610002 ON, P/N 230015 1 -2. Maximum allowable static unbalance force: 7. 928 inch/pounds 62 pounds or 9. 9 ounces) at 12. 80 inches aft of hinge line. Minimum allowable static unbalance force: 5.25 inch/pounds 41 pounds or 6.55 ounces) at 12. 80 inches aft of hinge line. Balance weights: P/N 260016 501 502. R'120F, S/N 660002, P/N 230015 503 504. hr~a-uimum allowable static unbalance force: 12. 00 inch/pounds 94 pounds or 12.5 ounces) at 12. 80 inches aft of hinge line. Minimum allowable static unbalance force: 10. 0 inch/pounds 78 pounds or 12.5 ounces) at 12. 80 inches aft of hinge line. Balance weights: 230016 503 -504. M20F, SIN 66003 thru 370040, P/N 230015 503 -504. Maximum static unbalance force: 7. 282 inch/pounds 57 pounds or 9. 1 ounces) at 12. 80 inches aft of hinge line. Balance weights:'PI'N 230016 1 -2. h120F, S/N 670041 gr ON, P/N 230015 503 -504. Maximum static unbalance force: 8. 00 inch/pounds 625 pounds or 10. 000 ounces) at 12. 80 inches aft of hinge line. Minimum static unbalance force: 5.25 inch/pounds 41 pounds or 6. 55 ounces) at 12. 80 inches aft of hinge line. Balance weights: PIN 230016 501 502. 6-2 IiEVlSED MAY 1979 Island Enterprises Elevators: M?OC,D&E. ~Iaximum allowable static unbalance force: 15.5 inch ipounds (1.22 pounds) at 12.75 inches aft of hinge line. XI70F. SIaximum allowable static unbalance force: 22.0 inch/pounds (1.725 pounds) at 12.75 inches aft of the hinge line. ~iinimum allowable static unbalance force: 20.0 inch/pounds (1.57 pounds) at 12.75 inches aft of hinge line. Rudder: hiSOC, D E, Maximum allowable static unbalance force: 6.9 inch/pounds (.57 pounds) at 12.12 inches aft of hinge line. h120F, Xl~ximum allowable static unbalance force: 21.0 inch/pounds (1.733 pounds) at 12.12 inches aft of hinge line. Xlinimum allowable static unbalance force: 13.0 inch/pounds (1.073 pounds) at 12.12 inches aft of hinge line. D. RIGCC;G ASD I. AileronRi~cring andAdjustment. a. Use a straight edge to line up controlwheels. Adjust tubes linking control wheels to center cross shaft untilwheels are level. b. Adjust vertical control tube so that the inboard aileron bell crank is located l;lij-in. to the left of center. c, Adjust control tubes in wings so that the center of the mo-ct c?ntboard hole in outboard bell cran4 is 4 and 39/~4 inches from the spar web. d. Adjust aileron push-pull tubes so that the ailerons are adjusted from OI re 2"rlnsop in die static position. All aileron travels are measured from the static position. e. ?he aileron stops are located at the outboard bell. crank assembly and are accessible through the access panel outboard of Sta. 147.75. f. Set: Fi~re 6-4 (aileron travel jig which is used at wing Station 147.75). g. See Fi~re 8-7 for aileron control system drawing. h. See Figure 6-2 6-3 and Section VI-D.B. for wing-heavy correction procedure. i. See page 6-7 for travel and rigging information. 2. ~rim Rigging and Adjustment. a. Set stops jlocated in the belly under the floorboard-accessible through the fuselage access panel) at trim for extreme travel (Figure 6-9~. b. Adjust screw at rear bulkheads !Sta. 194.0~ so that trim travels in excess of specification requirements. c. set stops at trim to travels given in control surface specifications page 6-7. d, See Fi~re 6-8 for trim control system drawing. 3, flapEii,ogin,o and Adjustment. a. Adjust inboard linkage and outboard hinge stop to obtain travels given in control surface s_Decifications page 6-7. b. SeeFigureG-lOforflap conrrolsysremdrawing. c. Adjust outboard hinge stop to align with aileron trailing adge. 6-3 REVISED NOVEMBER 1966 Island Enterprises d. Rudder Rigging and Adjustment. a. Raise aircraft nose (refer to Section n-C.1). b. Settrim controlinneutral. c. Clampco-pilot's rudderpedalsinneutral. d. Adjust rod end bearing on nose wheel interconrlect to center the nosegear. 2. Adjust bungee in left exhaust cavity to neutral. f. Adjust rod end bearing of coarol n:0- at main .;par and control tube at rear f~uelage burk- head and set rudder at approximately 1' to the ri~e g. Unclamp rudderpedal. h. Set stops of control tube (accessible through the access panels in the left side of the empen- nage) in stinger for rudder travels as given in Section VI-E. i. See Figure 6-5 for rudder control system diagram. j. See page 6-7 for travel and rigging information. k. SeeFigureG-4 fortravelji,o. 5. Elevator Rigging and Adjustment. a. Adjust the rod end bearing of control tube at control column for clearance of control shaft to firewall and control column to fuselage structure. b. Set trim control in neutral with stabilizer parallel to centerline of airplane. tube rear of c. Adjust rod end bearing of control tube at elevator attachment, and control at bulkhead for excess travel of elevators. d. Set stops (accessible through the access pa.lels in the left side of the empennage) in stinger for travels as given on page 6-7. e. Adjustbungees as described inSectionVI-E. f. See Figure 6-6 for elevator control system diagram. g. Seep~,oeG-7fortraveland ri~gin,oinformation. h. See Figure d-4 for travel jig. 6. Trailing EdgeTrimming. A special pair of wide-nose vice-grip pliars are to be used to bend the trailing edges as neces- sary (Refer to Figures 6-2 and 6-3.). To correct for left wing-heavy condition, berid down trail- ing edge on right aileron; to correct for right wing-heavy condition, bend down trailing edge on left aiIeron. 7. Hydraulic Flap System Bleeding (See Fi~res 6-10, 6-11. and 6-12.). When flap action becomes erratic or when repairs recIuire the replacement of actuating com- ponents, it is necessary to bleed the hydraulic flap system. Best results are achieved with the use of clean hydraulic fluid from a hydraulic fluid system bleeder (pressurepot) pressurized with air to approximately 35-40 Ibs. a. R~movehydraulicfiuid reservoirventcap. b. Disconnect hydraulic cylinder piston rod from jack shaft. c. Open bleed valve in T-fiaing at hydraulic cylinder. d. Pump actuating handle and observe flow of fluid from bleeder valve into catch pan. e. When fluid clear~ of bubbles and runs transparent, slide shaft and piston to bottom to expell air. f. Pump actuating handle to re-extend piston and shaft. g. Repeat steps e and f until all traces of air is removed from expelled fluid. h. Closebleed valveand i. Remove excess fluid from reservoir through side plug to re-establish proper level. REVISED NOVEMBER 1966 6-4 Island Enterprises FIGURE 6-2 TRAILING EDGE TRIMMING DIAGRAMS ILOMINi?L CO~IF!GLIRATiOr\l S') C· FIED CONFIGURATIOF! NOMINAI, CONFIGURATION \.090 t.070 MAX. NOTE: UNDER NO CIRCUMSTANCES MAY THE TRAILING EDGE BE BENT UP. ANY MODIFIED CONFIGURATION OPEN-HEAD RIVETS MUST BE REPLACED AFTER MODIFICATION. AILERON TRAILING EDGE TRIMMING g~L .os MAX. (BOTH DIRECTIONS) NOTE: ANY OPEN-HEAD RIVETS MUST BE REPLACED AFTER MODIFICATION. RUDDER TRAILING EDGE TRIMMING a-5 Island Enterprises FIGURE 6-3 APPLICATION OF TRAILING EDGE TRIMMING VICE-GRIP PLIARS iC~y ·-~;-:n 6-6 Island Enterprises E. CONTROLTRAVELA~ RICGI1~G SPECiFICr\TIOh'S (SEE FIGURE 6-4) 1. WINGFLAPS Measured from wirt;T chord with travel board at wing Stgdon 147.75. UP position 00 (alin with aileron) Tolerance 20 Takeoff position 15" GL120C,Eg;F) Tolerance i 1" Approach landing position 33" Tolerance 00 -2" 2. AILERONS hleasured from aiieron chord with aileron in the static position with travel board at wing Sta- tion 147.75. Down travel, both ailerons 8" Tolerance r 1" Down travel, both ailerons 8" Tolerance i: 1" UP travel, either aileron, may vary from 124i" to 17" with no additional tolerance. Static position from 0" to 2" down 3. RUDDER AND NOSEWHEEL Measured from fin c'nord with cavel hoard centered on river line at fin Station 13.5. Left travel 73 Right travel '3" Tolerance -O" i=L" for either With rudder pedals in neutral and with trim assist unit at zero spring travel, rudder and nosewheel settings are approximately 1' right, i2"right. 3. STXBILIZER nose-down setting (?~IZOC,D&E) 1" to 23~0 Maximum nose-down setting G~I?OF) ~4"to 2" ~ulaximurr nose-up setting C~?2OC,D&E) 44i" to 50 ~laximum nose-up serring (M20F) 51/40 to 5!/40 5. ELEVXTORS Measured from stabilizer c'nord with travel hoard centered on rivet line at stabilizer Station lS.O and with stabilizer at 00 thrust line. UP travel (M20C,D&E) 2·1" Tolerance i 1" Up travel UL2OF) 310 Tolerance i 7" Down travel (~20C,D&E) 10W Tolerance ii" Down travel (M20F) 23" Tolerance i 2" 6. ELEVXTORTR~1 ASSISTZ~NITS- With stabilizer set at 3,50 for nose-up flight, adjust trim-assist units for el- (Retractable evator-up angle of 19" i ~40at the zero spring-travel position. ~L1ZOD (fixed Gear) gear) aircraft must have an elevator-up angle of 13~" 4i" at the zero spring- travel position. ~30F: With stabilizer set at j.50 for nose-up flight. adjust trim-assist units for el- cvaror-up angle of ~5i" i 44" at the zero spring travel position. 7. ALLOWABLE FREE-PLAY LL~IITS Allowable fore and aft movement at stabilizer tip .13" Allowable vertical movement at stabilizer tip .10" Allowable vertical movement at rudder trailing. edge .08" REVISED NOVEMBER 1966 6-7 Island Enterprises rlu BUBBLE: PROTRACTOR 71 \d o C ;6 rn 33 STh 16.0 ch -----_s b ~L- ~2, n o z j;J ,EVATOR STABALIZER o r ;6 rn L n cn FIN 9PA (3.3 s=--·- ~L- RUDDER WING 6TA IC7.6 NOIE: SEE FIGURES 4-2 4-3 FOR STATION NUMBER CALLOUTS AILERON Island Enterprises ~1 o m a ;a m t7 /CA~ I Z In 0< 5? ;a c m a ;a `4Vl'll m ;o n o z o r cn v, m ADJUSTMENTS 3= (3 PLACES) z cn -I r -i a LUBRICATION APPLY z a(MIL-L-7B70) OIL TO ALL LINKAGE JOINTS. R HOURS-100 (See Fig. 2-9.) BUNGEE Island Enterprises 71 t, o I C 70 m o* rfh r-" r! d xl z -I ;a o r-· Y z r-7 in r F -I o c~S z ;o m m 2 LUBRICATION-APpLy L~ (MIL-L-7870) OIL TO ALL LINKAGE JOINTS, EACH 100 HOURS. (See Fig. 2-~.) P APPLY~POWDERL2D GRAPNITE TO 710001 BALL, CONTROL TUBE, EACH 100 HOURS. (See Fig. 2-9.) Island Enterprises LUBRICA.TION- APPLYL1(MIL-7-7870) 71 '2 OIL TO ALL LINKAGE JOINTS ~i EACH 100 tlOURS. (Seo Fl,. 2.9., APPLY -r;- GRAPHITE rn z 9 MIL-C-3278 GREASE TO m GUIDE BLOCKS, 4 EACH SIDE, m EACH 100 HOURS. (Seo Flg. 2-9.) 5~ am r 00 ;;O (h( O Z 5: Z --I r v, ·i v, f Z I? r 6 Ej Z Island Enterprises T1 C) c= 70 rn ch ItD a z Q r Y z r r -I c3 z LUBR ICAT IOtJ A PP LY ~MIL-G-3378 GREASE 59 ;o ~C- I LUBRICATION APPLY L/MIL-G-3278 GREASE TO ~cr SCREW THREADS (740021) EACH 250 HOURS. APPLY--c2GRAPHITE AND MIL-G-3278 GREASE TO GUIDE BLOCKS, EACH 100 HOURS. (See Fig. 2-9.) Island Enterprises ;D 1 ON ASSEMBLY NOS, 740002 AND 7400,s0-1, TRIM CONTROL WHEEL z CHAIN ADJUSTMENT IS MADE BY LOOSEN- ;D O< ING SIX SCREWS AROUND SI1AFT ON TRIM rn m AND ROTATING ECCENTRIC BUSH· mm ING, OI CHAIN (BACK r) :I SIDE) r S: Irir") z I P CHA;N ADJUSTMENT. BOL TS (2) ;a ALLEN WRENCH SOCKET ~TO HOLD BOLT WHILE NUT 1S LOOSENED) r SET SCREWS (2) HL18'-6-30 HI-LOK FASTENER AN363 1032 NUT GEAR BOX ASSEMBLY ti'. `~FE1` STOPS (REFER TO TRIM RIGGING 4 NUTS MUST BE LOOSENED BEFORE CHAIN AND ADJUSTMENT IN SEC- CAN BE TIGHTENED BY CHAIN ADJUSTMENT TION VI) BOLTS, STOP BLOCK ·j I Island Enterprises 'i 1 n ~L· RELEASE CONTROL m RESERVOIR o ;I! -a n o z r Y Y m 3e~ 5L v, I~ I~ HYD CYL o z HYD PUMP VALVE ASSY ?D m z o FLAP HANDLE LUBRICATION Apply d (MIL-Lo7870) OIL TO ALL LINKAGE JOINTS EACH 100 HOURS. (See Fig. 2-9.) Island Enterprises c, c AN6227-8 "O" RINGS (2) E-1517 SEALS (2) AN6227-1 "O" RING /HE-1516 SPRING 71 ap a c 0) 3: a ·~··,i AN6227-3 O RING ~3 S~t AN6246-3 s~ACK UP RINGS r s rn AN6290-8 O RING 1/4" STEEC BALL V) SPRING m r AN6290-S "O" RING 3/16" STEEL BALL HE-1518 SPRING AN6227-6 "O" RING (BETWEEN CAP AND SHAFT\ ASSEMBLY NO, HE-626 L- TURN THIS SCREW CLOCKWISE TO SLOW THE RATE OF "BLEED OFF" OF FLUID 8 12 SECONDS. Island Enterprises 'I, 71 o c ;o rn e r ';1 AN6227-16" O RING r z AN6246-16RING cl rn xl t~ in m r ASSEMBLY NOV HE-625 Island Enterprises F. POSITIVE CONTROLSY~TEXI I. Introduction. in and a. The purpose of this section is to assist service and maintenance personnel testing calibrating the SIooney PC System. Table 2 lists the most probable troubles that may be encountered and the procedures to be taken to isolate and correct the cause of malfunction. that Table 2 Para. 9 provides a step-by-step procedure for system analysis in the event does not cover the Drocedure. b. Reference should be made to paragraph 3 (Ground Test Procedure) for ground checking of the unit for proper vacuum settings, leaks, and command functions. Reference should be made to paragraph 5 (Operating Instructions) for proper iii-flight checking and setting of the unit. c. This section deals primarily with the two-axis PC system. Sc h made to tile. D~ertial Pitch Control (elevator control) system or to the hiagnetic i-leading Lock, as both of these systems are dealt with in a separateOperationh Service Manual, 2. System Description. a. General The system is a pneumatically operated two-axis automatic-control device, which sanses both roll and yaw while deriving its power from the aircraft engine-driven vacuum pump. The system consists basically of a gyro-sense element which meters vacuum pressure to a cylinder-piston servo assembly. On all aircraft in which this system is installed, these servos are attached to the aileron and rudder controls, providing for a dual-control system. ~ZOTE: The 1967 and subsequent ~IZOC,E F models have a turn coordinator which replaces the rate ~ro and operates by vacuum and electrical power simultaneously. The turn coordinator also replaces the turn-and-bank indicator in these models. b. Operation I. Stability and control of the airplane about both the roll and yaw axes is Lbtained by tilt- ing the rate-gyro (or turn coordinator) assemblyto a predetermined angle. This permits a part of the roll rate and a pan of the yaw rate to act on the sensitive gyro-rotcr ele- ment, producing an output signal. In this manner, a singlegyro elemant :s sensing motion about two axes-roll and yaw-the~eby providing basically a two-axis system. 2. Roll or y~y of the airplane caused by wind gusts, out-of-trim conditions, or airspeed changes displaces the rate gyro (or tum coordinator). The resulting output signal is coupled to a spool-sleeve rotary valve. The spool is rotated'inside the sleeve in pro- portion to both yaw and roll rates of the airplane. The spool moves to a location be- tween the vzcuum-su_Dply port and one of the outputports. The other output port is qDened to atmosphere, bleeding the vacuum. The resulting vacuum differential is cirec- red to the proper pneumatically operated servo so as to correct the original roll or yaw error. In straight-and-level flight,, the vacuum differential is zero and the servos are balanced. 3. Desired roll and yaw rate proportions of the total si~al are obtained by mounting the rate ~ro (or turn coordinator) at a predetermined incline angle from truehorizontal at cruise attitude. Changes in this angle, due to changes in the pitch attitude of the air- plane, orily partially compensate for the corresponding change inaircraftstability characteristics. For instance, as the aircraft pitches up to climb, the decreased air- speed and lower aerodynzmic loads necessitate more aileron control motion to main- tain stability. The corresponding change in rate-gyro (or turn coordinator) tilt angle produces increased roll-rate sensitivity, which partially compensates for the change in aircraft stability. The opposite occurs as the airplane pitches down and airspeed in- creas es. REVISED NOVEMBER 1966 6-17 Island Enterprises 4. Provisions have been made in this system to allow for a roll trim pilot command func- tion. This roll trim may be used to compensate for asymmetrical fuel and passenger loading and to optimize system performance in climb, cruise, and letdown configura- tions. During normal aircraft operation in low-speed climb, it is necessary to utilize a combination of right rudderlaileron control to maintain wings-level flight. Dispiac- ing the roll-trim knob to the right will partially compensate for this condition. Like- wise, during high-speed descent the normal left rudderfaileron trim required may be accomplished by displacing the roll-trim valve to the left. However, the application of the roll-trim valve is not intended to substitute for proper rigging of the aircraft control system. 5. If the aircraft is properly trimmed by means of roll-trim adjustment, the unit will main- tain an average heading over a fairly long period of time; however, the unit will not maintain an absolute preselected heading without the addition of a magnetic heading lock. For optimum performance the aircraft must be rigged to fly needle-hall (or turn co- ordinator) centered. 6. The system push-button disconnect, located in the control wheel, operates a pneumatic relay which provides vacuum to the gyro-sense element (or turn coordinator), When the push button is depressed, all servo vacuum supply is relieved and the system is im- mediately inoperative. The pilot may then command turns in the normal manner without overriding the system. Releasing the push button reactivates the system. However, normal maneuvers may be readily accomplished without disengaging the system, as over-power forces recluired are small and no damage will result to either the aircraft or the system. c. System Performance. The Mooney Lateral Stability Augmentation System is designed to be capable of maintaining aircraft ecF~ilibrium over the o_Derational speed range under conditions that would otherwise cause rapid spiral divergence. The device is also intended to maintain lateral stability and prevent excessive changes in heading and airplane gyrations in turbulent air. 3. GroundTest Procedure. Perform the following ground tests and procedures after completion of component replacement and prior to starting engine or conducting flight tests: a. All vacuum lines must be free of kinks and sharp bends. Make certain that lines have been purged or blown free of foreign panicles before operating the system. NOTE: Do nor operate the system at any time with lines disconnected From servo units. do Also, not fly aircraft with servo unit bibs capped or lines plugged when they are connected to servo units. Expansion within servo cylinder can block movement of ailerons when aircraft is flown to altitude. b. AircraftVacuum (PrimaryVacuum) the Stan engine and increase the rpm to 1700 (If desired, an external vacuum pump may be utilized if the vacuum source is attached to the engine side of the aircraft vacuum relief in. valve.). Adjust the vacuum-relief valve to 4.75 4 .25j Hg. on the gyro horizon or directional gyro case. The primary vacuum reading on the PC system will be approx- imately 1/2 in Hg. lower than that read at the ~ro horizon (See ~ig. 6-15 and Fig. 6-17, Sheet 2, PC 3.). ~Iake cenainthatthe vacuum relief valvl ·sl!d regulator arefunctioning properly. NOTE: The vacuum-relief vdlve setting shoula bemaintained onthehigh side of the limit. CAUTION Permit no oil, grease, or thread lube, etc. to enter internal parts of the dry vacuum pump. Clean all lines before reinstallin,o. Do notusethreadlube on fittings. 6-18 REVISED NOVEMBER 1966 Island Enterprises c. Cutoff Valve Operation i. The pneumatic cutoff vahe Inounted in the control wheel actuates the pneumatic relay sequencing vacuum to the rate ~ro valve (or turn coordinator). FIGURE 6-13 CUTOFF VALVE OPERATING CHECK DIAGRAM PILOT VALVE To I~eh'-l To VACUuw SOURCE _ REMOTE ·CC GYRO OR TURN COORDINATOR t ApPLy SUCTION TO f HERE ROLL TRIM VALVE To CUT-OFF OTO10 in. GAGEHG.VACUUM VALVE i j!iI f 2. Disconnect,orzy line at pilot valve, insert aTee as per Figure 6-13 with a suction gauge on one side and the other line open so that suction can be applied. 3. By mouth, apply about 5 in. Hg suction. Valve should not leak more than 2 in. Hg in 30 seconds. 4. Depress valve and vacuum should drop immediately, proving that tubes in control wheel and valve are not restricted. 5. Upon release of valve, burton should return immediately to its normal position. d. PilotValve-Operation The pilot valve is in effect a pneumatic relay that shuts off the vacuum supply to the rate gyro valve (or Nm coordinator) when cutoff valve is depressed and at the same time relieves the vacuum in the servos so that the system does not load the controls when system is cut off. 1. Proper a. To test pilot vahe. disconnect the gray line as shown in Figure 6-14 on the se- qsenced vacuum side and attach a 0-10 in. vacuum gauge. Witfi vacuum on the sys- tem and the cutoff Valve not depressed, the reading on gauge should be 4.0 in. Hg.+ (wiSn primary vacuum at 4.75 in. Hg.!. 6-19 REV1SED NOVEMBER 1966 Island Enterprises FIGURE 6-14 PILOT VALVE OPERATING DIAGRAM TO VAOuvn SOURCE In TG PUSH BUTtON PILOT VALVE VALVE ill' r OTO10 ilGHG VACUUM GAUGE b. tTFon depressing cutoff valve, gauge should drop to 0 in. Hg. If vacuum is not re- off lieved and there still remains a reading on gauge, pilot valve is not shutting completely and should be replaced. e. PrimaryVacuum Reading FIGURE 6-15 PRIMARY VACUUM READING DIAGRAM (1965 1966 MODELS) TEST PO I NT ~I REMOVE CAP AND ATTACH 0-10 in, HG VACUUM GAUGE ON TO TEST BIB GYRO i 0-10 (A) (B) PRIMARY VACUUM REMOTE GrRO READING (A) TEST VACUUM GAUGE TO READ (~PRIMARY (8) LSA-I GYRO 6-20 REVISED NOVEMBER 1966 Island Enterprises f. Gyro Rotor Speed Adjustment (1965 8 1966 models) To assure proper gyro response it is necessary that the gyro rotor be operated at the proper rotor speed. Fast active corrections. Rotor speed can be checked by the following test: (A vacuum reading of 3.5 in:Hg..il.0 in. -0 in. Hg.. is recommended for proper operation.). FIGURE 6-15A GYRO ROTOR SPEED AD~USTMENT (~965 8 1966 MODELS) 1. Installa0-10 RE3tRI ttOR in.Hgvacuumgauge as shown in FigureG-15A. Con- ADSUSTMENt ~37 ,TESt Ble nect the vent side to test bib#2. Connect the suction side to test bib 81. The vacuum gage will in- dicate the vacuum (3.5 in. Srg, f1.0 -0 in. Hg) across the rotor which control~ its speed. G'YRO XtEST Ble n\ i 1\1 2. To change the rotor speed, adjust point ,U3, shown in Figure 6-15A, SUCtlON VEHt /I fO Obtain the required 3.5 in. Hg (f1.0 -0 in. Hg) on the vacuum O 0_10ii-~9. gauge. Also ref~r to FigureG-17, Sheet 2, PC 2. Clockwise rota- VACtIUM tion of adjustment #3 on Figure GAUQE 6-15A will decrease the vacuum REnotE GYRO reading. NOTE: This adjustment is EXTREMELY IMPORTANT, and care shauld;betakento make certain this adjustment is accurate. With Group i and Group nI auto- pilot installations, the differential vacuum reading across test bibs~land j~2 (Figure 6-15A) should read 4 in. Hg. 3, For further Group I and Group III autopilot maintenance information covering 1965 8 1966 models, refer to Operation Service Instruction manuals 11968-1 (Mooney Nzv-couplerfHeading Lock) and 11968-2 (Mooney Pitch Control). Manuals 11990-1 and 21990-2 cover 1967 and subsequent models. 4. Replace the test bib caps and make certain that no leaks exist around these caps. Manually displace the roll-trim knob counter-clockwise as far as possible, ~he control wheel should tend to turn to the left. Turn the roll-trim valve fully clock- wise and the control wheel should tend to turn to the right. Center the roll-trim valve. During taxi operations the control wheel will tend to turn opposite to the air- craft if the ~ro is properly phased. 4. Roll-Yaw System. a. Rate Gyro Val~e Cencermg (1965 1966 models) Vacuum differential may result from the rate-gyro valve be~ing off center while the aircraft is stationary on the ground. Yawing the aircraft will precess the rate gyro. In this manner it may be deten?ined whether or not the pneumatic null is permanently offset. If there ap- pears to be a permanent offsk to the right or left, greater than a .2 in. Hg differential, the rate-gyro valve should be repositioned. Only minute movements of the valve stub are re- quired. b. Roll-Trim ValveCenterin,o rorr Roll trim valve stops are factory adjusted and should not be moved. The knob should be centered (dot at top) with same degree of rotation right and left (Fi~re 6-17, Sheet 2, PC 3). NOTE: 1967 C, E 8 F models have a turn coordinator which has a roll-trim knob on the in- strument front. If the turn coordinator is removed (rec~iring removal of the knob), the knob should first be centered for ease of relocation. REVISED NOVEMBER 1966 6-21 Island Enterprises FIGURE 6-16 RATE GYRO VALVE CENTERING DIAGRAM (1965 a 1966 MODELS) ~UTE: ~lake certain aircraft i- in CE*TEIIUG ITUS wiIlgs-level attitude for this check. ILLEN SiT IOE· ·urrOCr C*LI1F I1LOrS~I Adjust vahe to center 10-0-10 in. r rPvEri*~ Hg. differential gauge installed a- cross red and green #yro bibs. It will be necessary to temporaril~ j remove the red and green servo tubes for this test. i SOTE: The turn coordinator in- stalled on 19(i7 sub·e- quent models is pre-centered and the gyro speed is pre- set at the factory. The in- strument should be replaced when a malfunction is found that i; attributed to the in- ku·k·l*~l J I strument itself. GaEE* if the c. Tazri the aircraft to check for proper movement of the controls. Yaw to the left to see wheel control wheel moves to the right. Yawinp to the right should nra;te the control turn wheel moves to the left. if the rate gyro or turn coordinator phasing is reversed in the direction of the turni the tubing leading from the ~jro or rum coorhinator to the servo is reversed at the bulkhead fitting. 5. Operatin,oInsrructions and the cutoff a. Before takeoff. check force, required to overpower the vacuum servos. Depress button to see if vacuum forces are rdieved. b. Climb to a safe altitude in smooth air and trim airplanefor straight-and-level flight at cruise configuration. IF it is apparent that aircraft is notproperly rigged. rerigging will be necessary before continuing with the flight test. c. Depress the control wheel mounted cutoff button; the system should become inoperative. Upon release of this cutoff button the system should re-engage. Depress the cutoff button and command a era. Release the cutoff button and the aircraft should re- cover smoothly. d. Szrring the Per :·oli rrirll rnnr-nl ~nr' ~i!! normally compensate for asymmetrical fuel and passenger !nads i·, rn~i-- T~iilj· r;zlkcted roll trim settings aenerally will not bank the aircraft Illsre than 'L To J ~r one burrh of standard-rate turn. NOTE: The roll-trim %nob should be aPF..~hlll:2T-iJ centered during level Flight. However. a roll-trim knee setting as much as 90.';rom center during wings-level flight doe: not necessarily indicate a Pr3 system mali~lnction. has no rlutche~ e. The PC system may easily be overpowered at any time. ~ince the system or electric motors. it can be overridden indefinitely with no resulting harm. f. Upon completing the flight test. make a log hook entry showing that the PC (or autopilod system has been test flOwn b~1211 appropriately rated pilot (Ref. FAR Part 91.16 A.!. 6. Emergency Procedures. a. If a malfunction should occur in the unit. it can be overridden merely withpressure on the flight ~conrrols, and the entire system can be disengaged by depressing the pushbutton. 6-22 REVISED NOVEMBER 1966 Island Enterprises b. If a loss of vacllum supply occurs as indicated by a low-~acuuln ~arllirlR li~ht. the ~vsrzm will become inoperative. So adverse effect ilpon the air-worthiness of the aircraft will be encountered. check for leaks in the entire vacuum system should be conducted as soon as possible. If no leaks are found. check the vacuum source (pump) and the aircraft vacuum- relief valve. hIaintenance. a. Once the system has been adjusted, it should require no further maintenance other than in- spection of the various units for security and general condition. h. The gyro filter should be replaced as required. X partially clogged filter will produce a sluggish gyro sense-element response. However. the turn coordinator jinstalled on 1967 and modds'i will function by electric power should the vacuum filter become clogged. c. If the high or low vacuum light illuminates, inspect the entire aircraft vacuum system for leaks, stop_Da,oes, etc. 8. Trouble Shooting. Table 2 below lists the most li~ely-to-be-encountered flight control malfunctions, with causes and steps to be taken to isolate and correct the malfunction. In the event that a malfunction is not covered here, refer to paragraph 9. TABLE 2 POSITIVE CONTROL SYSTEM TROUBLE SHOOTING MALFUNCTION PROBABLE CAUSE REMEDY I. Hi or I,o vacuum Faulty vacuum pump or Perform Test gl and adjust relief vafre. light. vacuum if necessary. svirch. Faulty Replace switch. 2. Aircraft hunts in (1) Partial closure or leak- Perform Test ,"2. ni~ht. ing servo vacuum line. (2) Improper ,oyro operation. Perform Test 93. (3! Improper vacuum supply Perform Test ~1 and adjust to valves and instruments, vacuum if necessary. (4) Faultyservo. Perform Test ~2. 3. Xircraft does not (I) incorrecttrim of Check aircraft rigging and aircraft. hold directional adjust as recluired. heading. (2! Exco,ss friction in Examine the primary control to determine system. system that no excessive friction exists. ~Lubricate all hinge points as depicted in Figure 2-9.) (3) Improper vacuum to valves Perform Test ~1 and ~2 and and instn~ments. adjust vacuum. (8 Faulty rategyro. Perform Test f3. REVISED NOVEMBER 1966 6-23 Island Enterprises TABLE 2 (Conrinued) MALFUNCTION PROBABLE CAUSF, REMEDY 4. Aircrafr recovers in one (1~ Restriction or leak in Perform ~est ,"2. direction but not the I servo vacuum line. other. i2, I.oose or disconnected Perform Test a?. servo cable. (3`! Inoperztive servo. Perform Test 92. t~i Faulty rategyro or Perform Test ge. Replace turn coordinator. turn coordinator. 5. .-tircrzft tends to roll i I.eak or pdrtial rznrictionin Perform Test to one side. servo vacuum line. !2'1 Improper gyro operation. Perform Test g3. !3,' I72Ul~y,-ervO; lo0seordis- cable. connected Perform Test j7,. Faulty rate gyro, valve Perform lest f·l. off center. (55 Faulty turncoordinator. Replace turn coordinator. Continuous wheel osci- (li Gyro rotor speed iinproper. Perform rest 43. lation in smooth air. (2j Too hi~h vacuum setting. Perform Test 51. 13) Inoperative rate gyro. Perform Test ~4. (4! Faulty turn coordinator. Replace turn coordinator. recovery from turn (1~ Excessive friction in Examine the primary control in one direction. primary control system. system to see if excessive friction exists. Lubricate all hinge points as depicted in Figure 2-9. !1~ Leak or partial restric- Perform Test e2. tion in servo line. i3i Loose ordisconnectcd Perform Test servo cable. 14i Faulty servo. Perform Test ,"2. (5! Improper rate gyro operation.) Perform Test REVISED NOVEMBER 1966 \;-24 Island Enterprises 9. Trouble Shoorin,oTests. a. The following tests are to~ be conducted as directed in Table 2. As each of the tests is con- ducted, the reading or indication should be if, in any test, the reading differs from the correct indication, follow the corrective measures as indicated. In the event that malfunctions are not covered specifically in Table 2, the following tests should be used as a step-by-step procedure for thorough system analysis. b. Test #I-Vacuum Settings Start the engne and increase the rpm to 1700 gJhen desired, an external vacuum pump may be utilized if the vacuum source is attached to the engine side of the aircraft vacuum-relief valve~. Adjust the aircraft vacuum-relief valve to produce 4.75 Hg(-I-.25 in. Hg) output as read at the case of either the ~ro horizon or directional gyro (See Figure 6-15 and Figure 6-17, Sheet 2, PC 3.). Always adjust to the high side of the limit. c. Test 32-Vacuum Line and Servo Leak Test Visually inspect all lines to eliminate possible defects such as kinks, restrictions. or obvi- ous breaks. Disconnect line from the back of the gyro sense element and install vacuum-test gauge in the open end of the line (See Figure 6-15 and Fi~re 6-17, Sheet 2, PC 2.!. Rotate aircraft controls so as to extend the piston of the respective servo. This will provide a vacuum in the system which may be read off of the test suction,azuge. Hold the control surfaces solid- ly. making certain that the piston is stationary. If no leak in the system exists, the test suction gauge reading will remain constant. Exercise care that all tubing connections are d~t and will not produce a leak. When checking that tubing which connects to the roll-trim valve, they must be removed from the valve and securely plugged. The valve has atmosphere- bleed ports which preclude this leak test unless the tubing is plugged. Li· TeSt~3-GyrOROtOT Speed Refer to Figure 6-15i\. Attach a 0-10 in. Hg vacuum gauge to test bib,U1. With the vacuum relief valve set as described in paragraph 3.b., a reading of approximately 4.25 in. Hg should be obtained at this point. This reading will vary depending upon the setting within the coler- ance of 1.75 in. Hg (+.25 in. Hg). UncaD rest bib 82 as shown in Figure 6-15A and Figure 6-17, Sheet 2, PC 2, and attach a line from the vent side of the suction gauge to test bib f2. Adjust the set screw called out in Fi~re d-15A andfigure6-17, Sheet 2, PC 2 to a reading of 3 in. Hg(f.5 in. Hg, -0 in. Hg!. e. Test ~d-Rate GyroValveCentering Refer to Figure 6-16. (1965 1966 models). Disconnect red and green tubing from back of rate ~ro. Attach a differential gauge across~the two·bibs and rotate valve until a 0 in, dif- ferentialis obtained. Yaw aircraft and note needle deflection on differential gauge indicating rate gyro deflection. When aircraft stops yawing. gyro should come back to center within ~.2 in. Hg. The rate EIY'O O' Nm coordinator should be replaced if it does not center properly. REVISED NOVEMBER 1966 6-25 Island Enterprises f. Test ,U5-lnstallation Inspection Rotate the aircraft controlwheel. The attachment to the respective servos must be tig'nt and the servo piston extended with rubber seal not stretched (See Figure 6-17, Sheet 3, PC 8.). Examine the primary control system to determine that no excessive friction exists. Lubri- cate all hinge points as-depicted in Figure 2-9. Also refer to Figure 6-17, Sheet 3, PC 4 when trouble shooting system. Be sure the chain between the aileron bell crank and the aileron servo does not have a twist. This can be corrected by repositionin,o the rubber boot on the servo. Refer to Figure 6-17, PC 2. 3, ·i. 5, 6, 7. and schematics for proper line routing and color coding. SHOP NOTES 6-26 REVISED NOVEMBER 1966 Island Enterprises ~22! PC 1 "C, m C 133 F,S, 125 uc U F,S, 103 z -c--5TA.16 F,S, 03 ~1415;:-IrQ~Tfv, 2" m ~lsfi' n 'i; o z o i: r AND RUDDER SERVOS v, TUBING YRO CROSSOVER SEE PC 2 SEE PC rn OTE 1 5 NOTE 2 NOTE 3 AILERON SERVO SEE PC 4 PILOT VALVE, VACUUM REG, CONTROL WHEEL SEE ec 3 W,S, 59.25 NOTE 1 500-6 I-tvCO GROMMET 1N VI.S. 43.50, W.S. 59.25. W,S, 147.75 G51B NYLON CATERPILLAR CROMMET 1N ALL OTHER RIGS. W.S, 103.5 NOTE 2 AN742-60 CLIP, ANS16-8-R7 OR EQUIVALENTS. ~n NOTE 3 3/ 81' I.D, 7" LG SCUFF COVERING FLEXCO ~i 4199 OR EQUIVALENT. Island Enterprises SHEET 2, C7965) INSTALLATION ADIUSTMENT SET SCREW PRIMARY VACUUM FOR 3 in t.5-.0 Hg DIFFERENTIAL BETWEEN BIBS 1AND 2 AFT RUDDER SERVO 2980 TEE 11873-10 2 PLACES Alft FILTERS PC 2 GREEN I BLACK RED 1190-25 I: REMOTE GYRO GRAY ADEL 668-12-6 FR CLAMP or TEST BIB TEST BIB EQUIVALENT NO. 2 NO. i FORWARD RUDDER SERVO 2980-1 AIRCRAFT VACUUM REGULATOR PC 3 ROLL TRIM VALVE 2985 PUSH BUTTON i VALVE 2960 I' x PILOT VALVE 1124'6-3 FITTINGS 2 PLACES 8-28 Island Enterprises SHEET 3 ~CATERPILLAR GROMMET WING STA, 147,75 i I; 29s3~ AILERONSERVO PC 4 AILERON BELL CRANU 210152 BRACKET .'i r. A6 CORBIN CLAMP 3/8 O.D. POLY FLOW (RED) L.H. YjlNG INSTALLATION (GREEN) R.H. WING INSTALLATION 1 I AN36j-524A NUT I AN970-5 WASHER 500-6 HYCO GROMMETS PC 5 ADEL 758-6 CLAMP OR 3" G518 NYLON CA;TIERPILLAR~ EQUIVALENT Z PLACES GROMMB US.E 3M 2·140-2609 kDHE'S'rW;E OR EQUlVA'LENT SECURE WITH: AN515-8-R8 2 P'LI;ACES SCREW el AN365-832A NUT 500-6 HYCO GROMMET F.S. 103 2" STRIP G51B CATERPILLAR GROMMET USE 3M 2140-2609 6-29 ADHESIVE OR EQUIVALENT Island Enterprises SHEET 4 (1965 PC SCHEMATIC) AIRCRAF~ YACUUY REGULATOR IILICI: PILOT VALVE BUtr (IUCL: 2965 DIRECTIONAL I I I IGYRO GYRO I I I I HORIZON tPFI BL*CX BUCI: ROLL Ti~lll PUSH VALVE BUTTOX 2385 VALVE 2960 tREr GREEI( I I RED FED RED GI1EEII, GIEEN LEFT AILERON SERVO 2983 1 Icnrw I I IRED RIGHT AILERON SERVO 2983 LEFT SEPUEWCED PRIYI~PI FIGHT TUlln VltVUY Y*CUUY TURH 11900-25 REYOTE GYRO I(ED FORIARD RUDDER SERVO 2980-1 AFf RUDDER SERVO 2980 CREEII 6-30 Island Enterprises SHEET S (1966 INSTALLATION) FORWARD RUODER PUSH BUTTON ROLL TRIM VALVE SERVO 2980·1 2985 VALVE2960 AFT RUDDER 5ERY0191~ AILERON SERVO 298) WING STA. 147.75 1~ PC 6 fr\u AILERON BELL CRANK BELL CRANK EXTENSION ASSEMBLY 1783 REa.. GROUP 1 8 3. OPT. PC INSTALLATION(I INCH) TEST 818 NO. 1 REMOTE GYRO 119830 AIR FILTERS AIRCRAFT VACUUM REGULATOR TEST 818 NO. 2 o PILOT VALVE O 6-31 Island Enterprises SHEET 6 (1966 SCNEMATIC) AIRCRAFT VAaJUI RH;OLATOR BLAQC BLACI( tR*Y _I T\L rY leurx 11#Oj0 PILOT BLACK FILTER VALVE REF. 2~5 DIRECTICE14L I I nCRIZCNTAL GMK) I I I I OYRO ROLL TRIM VALVE 2985 RED BcACn tiiEEN C~A'I I ICUJOFF an, I I VALVE PILOT CCFFTROL 2S~Y1 WHEEL GREEN RED t1EW LEFT nlLERON i I R!CHT AILERON SERVO I I SERVO 2983 1 1 298] GREEh FCRYAKD RCM)Ea SERVO 29801 AFI RUDDiS SERVO 2980 RED 6-32 Island Enterprises SHEET 7 (7967 ON INSTALLATION) PUSH BUTTON VALVE RUDDER TUBES a TURN COORDINATOR ROLL TRIM CONTROL IO·COB FILTERS 1 3 I RUDDERSERVOS ROLL TRIMVALVE I~ ~s-" VACUUM O~d REGULATOR BULKHEAD FITTINGS PILOT VALVE TURN COORDINATOR INVERTER AILERON SERVO REVISED NOVEMBER 1966 6-33 Island Enterprises SHEET 8 (1967 g ON SCHEMATIC) BLACK BLACK VACUUM BLA_CK_ I 1 REGULATOR BLACK I ~L. 1. ~L I BLACK FILTER BLACK PILOT VALVE MIS BIB PERMANENTLY CAPPED TURN COORDINATOR v FfinHN1S GRAY CUTOFF VALVE GREEN (PUSHBUTTON) LEFT WING AILERON AT PILOT CONTROL SERVO (RIOHT TURN) WHEEL RED RED I n_ GREEN RIGHT WING AILERON SERVO (LEFT TURN) RED FORWARD RIGHT TURN AFT LEFT TURN GREEN RUDDER SERVOS 8-34 REVISED NOVEMBER 1966 Island Enterprises SECTION FUEL SYSTENI Island Enterprises SECTION VII FUEB. SYSTEM A. GENEIUL The fuel system consists of inte,oral sealed fuel cells located in the front portion of each wing. These cells feed to a selector valve which includes a strainer and sump drain. From the selector, fuel is fed to the electric boost pump, engine-driven pump, and then to the carburetor or fuel injector. 13. TROUBLE SHOOTIf*TG Troubles peculiar to the fuel system are listed in Table 3 along with their probable causes and sug- gested remedies. When trouble shooting, check from the power supply'to the items affected. if no trouble is found by this method, the trouble probably exists inside individual pieces of dcluipment; which may be removed from the aircraft and an identical unit, tested and known to be in good con- dition, should be installed in place. TABLE 3 FUEL SYSTEM TROUBLE SHOOTING TROUBLE CAUSE REMEDY Fuel gage not indicating. Broken wire Check and repair. Transmitting unit faulty Replace. Float hung in fuel cell Check and repair. Circuit breaker out Check and reset. Fuel gage indicates full incomplete ground Check ground connections at fuel when tanks are not full. transmitter in tank. No fuel pressure indica- No fuel in tanks Check and fill ranks. tion. I~efective fuel pump Check pump for proper fuel pressure buildup. Check for obstruction in elec- tric fuel pump screen. Check engine fuel pump diaphragm and check-valve. Pressure low or pressure Obstruction in inlet side Check fuel lines and remove obstruc- surge. of pump tions. Faulty diaphragm in en- Replace pump. gine pump Check fuel lines and repair or tighten. 7-1 Island Enterprises C. REMOVAL AND INSTi~LLATION OF FtrEL PUMPS i. Electric Fuel Pump Remova1(1964 ON). a. Removetheelectricallead attheknifedisconnect. b. Disconnectground wire. c. Disconnect outlet hose and drain line. d. Removeleftexhaust cavitypane1(310010). e. Disconnect pump inlet line (from inside). f. Remove jam nut and washer from pump inlet fitting. g. Remove clamp and lift pump off attach bracket. 2. Electric Fuel Pump Remova1(1962-1963 M20C; 1963 M20D). a. Removetheelectricallead attheknifedisconnect. b. Disconnecttheinletand outletfuellines. c. Remove two fuel pump mounting bolts and carefully removepump. d. Hold the pump manually and turn the cover in a counterclockwise direction and remove core. e. Carefully remove the screen and rinse it in gasoline or kerosene to thoroughly clean it. If screen is badly distorted or collapsed, replace it. f. Clean fuel pump cover in the same manner as in Step "e". 3. InstallationofElectric FuelPumps. Reverse procedure above. 4. Engine-driven Fuel Pump. Refer to the appropr;ate Lycomin,o overhaul manual for instructions in removal and assembly of the engine-driven fuel pump. D. REMOVAL AND MSTALLATION OF FUEL SELECTOR VALVE i. Remova1(1964 &ON). a. Removefuel selector valvehandle. b. Unscrew quickdrainpull ring. c. Disconnect right and left fuel inlet lines at valve body. d. Remove fuel outlet line at body. e. Remove four screws holding fuel valve assembly to mounting plate(610038). Fuel valve assembly can now be removed. f. See Figure 2-4 for illustration of fuel selector valve assembly. 2. Remova1(1962-1963 M20C; 1963 M20D). a. Remove fuel selector valve handle and pointer. NOTE: Use caution when removing pointer plate as this plate releases the tension of the detene pin and spring. b. Remove detent mechanism (610021) carefully. c. Remove ri~t and left fuel inlet lines at valve body. 7-2 Island Enterprises d. Remove fuel outlet line at valve body. e. Remove four screws holding fuelvalve assembly to mounting plate. Fuel valve assembly can now be removed, 3. Installation. Reverse the procedure above. E. FIELD REPAIR OF FUELTAMS 1. General. This instruction establishes the procedure to be used in repairing the integral fuel tank. Tank repairs should not be attempted untilthese instructions are read. 2. Approved Materials. a. Sealants: (NOTE: Sealant must meet U.S. Government specifications as indicated.) A2 or CS3204-A 1/2, A2 Brush coat sealant. ~ES-8802 ClassA) PR1~22-B 1/2, B2 or CS3204-B 1/2, B2 Filleting compound (hi~EES-8802, Class B) wing-wallpanel sealant. I?IZ1403-G-B2 Sealant-removable access panel. b. PR1005-L Protecting-coat sealant. c. Gloves-Polyethylene d. Turco 657 T~iipe Solvent e. Cheesecloth f. Turco LeaBDetector g. Methyl Ethyl Kegton (thinner for PR 1005-L) All of the above materials may be obtained from your local Mooney distributor or dealer. Sealants may be obtained from either the Products Research Co.,~(PRXXX) at the follow- ing address: 5454 San Fernando Glendale, Cdlifornia, 91209; or Chem Seal Co., (CSXXXX) at the following address:Roa4 120 Sherman Wag, Sun Valley, California, 91352. REVISED JULY1980 7-3 Island Enterprises 3. Handling and Mi~ing· Sealant. a. Sealant Material Characteristics: 1. Application life is the time that the mixed compound remains suitable for application. Application life is always based on standard conditions of 750F and 50~ relative humidi- ity. For every 100F rise in temperature, application life is reduced by half, and for every 100F drop in temperature, application life is doubled. High humidity at the time of mixing shortens the application life. 2. Maximum unopened container storage life is six (6) months at 850F. TABLE 4 TANK SEALANT APPLICATION LIFE AND CURING TI~UE AT 750F AND 50 PERCENT RELATIVE HUMIDITY: PR 1221 SEALANT Class A Tack-free Time tin hours) Curing Rate tin hours) Application Life tin hours) PR1422-A 1/2 10 30 1/2 PR1422-A2 36 72 2 CS3204-A 1/2 8 30 1/2 CS3204-A2 24 72 2 Class B PR1422-B 1/2 10 1 45 1/2 PR1422-B2 36 1 72 2 CS3204-B 1/2 8 30 .1 1/2 CS3204-B2 24 12 2 PR14,03-G-B2 ACCESS DOOR SEALANT Class B B-2 10 36 2 b. Mixing of Sealants 1. Handmixing. 2. Kits consisting of the proper proportions of base compound and accelerator should be used. 3. Slowly stir, to avoid excessive air entrapment, the accelerator into the base compound and thoroughly mix approximately seven to ten minutes. Be sure to scrape the sides and bottom of the container in order to include all compound in the mixture and to in- sure uniform blending. Scrape mixing paddle periodictillg to remove unmixed compound. 7-4 REVISED JULY1980 Island Enterprises 4, Take a small amount of sealant from the mixture with a clean alumnium strip and spread the sealant, then visually examine the film of sealant to ascertain if the accelerator is visible in particle form. If particles of accelerator: are visible, continue the mi~ing operation. If coarse particles of accelerator persist after mixing, the mixed batch and rem~iTlinP- accelerator willbe rejected. 5. Put a small amount of sealant in the accelerator container and mix to assure that all of the accelerator is mixed into the sealant. 4. Sealant applicationIns~uctions. The following instructions are for the reapplication of sealant removed in order to repair tank leaks. a. BrushSeakant 1, Apply a brush coat of sealant compound PR1422-A 1/2, A2 or CS3204-A 1/2, A2 over seams, rivets, nuts, and bolts if removed for repair. 2. A one-inch stiff paint brush is recommended for this operation. Brush strokes should be parallelto seams forcing the sealant into all gaps. Use a circular brush action to deposit an even coat of sealant around rivets, and bells. Coat should be approx- imately 1/32 of an inch thick. 3. Coll3iderable brush action should be used to force sealant into all small crevices to ob- tain good adhesion. Air pockets trapped under the sealant due to improper application will open up in the form of a hole or void soon after it has been applied. Repair should be made by pressing the sealant in place with 9 spatula while it is still in the applica- tion life state. 4. In cases where the to_D of a fla~ge is .040 inches or less and where application of a suc- cessful fillet would not be clearly defined, apply two brush coats of sealant compound in appro~imately 1/32 inch thick coats. Allowfirst coat to cure approximately four hours or until it becomes nibbery before application of the second coat. The second coat should extend 1/4 of an inch past the previous coat. b. 1. Generdl Req~rirements. a. Filleting sealant (PR1422-B 1/2, B2 or CS3a04-lj 1/2, B2) must be tack free. b. See Figure 7-5 for typicalfillet size. c. Filleting sealants laid on intersecting joints shallbe joined together to produce a continuous fillet. d. All and hard to reach areas should be sealed first, to prevent the possibil- ity of their being overlooked or incorrectly sealed. REVISED JULY1980 7-5 Island Enterprises FIGURE 7-1 TANK SEALANT APPLICATION DIAGRAM TYPICAL FILLETS FOR FUEL TANK REPAIRS TYPICAL PR 1422 or CS 3204, Class B APPLICATION 2415 RTb~ J MAIN SPAR (REF) i -r I EXTEND 1 I 3/8" TO SEAM1/2~AST COAT \i/ APX 1/32" 3/8 TO1/2" FILL VOIDS, GAPS HOLES FIRST STEP SECOND STEP BRUSH-COAT FILLER 3/16" TO 1/4" TE~ICKNESS r d 1/16" APX SEALANT PR 1005-L THICKNESS 3/16" to 1/4" (Ij FILLET SEAL ALL SEAMS WITH CLASS B INSIDE TANK APPLY PR 1005-L OVER ALL SEALc~NT. EXTEND BEYOND SEALANT 1-INCB. THIRD STEP FOURTH STEP APPLY BRUSH COAT OF CLASS B TO ALL FASTENERS- 1/32" TO 1/16" THICK. 7-6 REVISED JULY1980 Island Enterprises 2. Application of Fillets. a. Use a spatula or extrusion gun with 1/8 inch to 1/4 inch nozzle openings for ap- plying filletinp compo;md on the edges of all seams. b. If an extrusion gun is used, hold ~un perpendii~ular to seam when applying filletirSo compound so that extruded sealant will be packed tightly. c. Use a spatula to pack sealant firnilv in place; work out air pockets and properly form each fillet. c, Protective Coating Procedure (Brush). i. Brush on a smooth, coat of PR 1005-L over sealant with a paint brush short, even strokes. The fihn should extend one inch beyond the sealant on td the ad- jacent metal. 2. Allow the top coat to cure 20 minutes at 750F or until tack-free. 3. Apply second brush coat of PR 1005-L. 4. Every effort mustbe takento obtain a complete bubble-free, continuous top coat.· Do not try to rebrush over areas during the drying period as this will only cause dragging or will break the contin~ty of the coating. d. Senli~P of Removable Panels. I. General Req~ements, a. Clean metal surfaces to be sealed with Turco 657 Wipe Solvent or M.E.X. Do not allow solvent to dry on surface; wipe off to prevent redeposit of con- taminants. b. Cleaned surfaces need dry only 5~to 10 min~rtes before application of sealant. Sealant should be applied as soon as possible after cleaning. c. Parts should not be stored or handled in any manner which will allow fingerprints, dust, dirt, and other foreign substances to contaminate the surfaces to be sealed after the cleaning operation. 2. Sealin~g·Procedure (for upper right wing-walk access panel). a. Apply a coat of access door sealant PR1422-B 1/2 or CS3204-B 1/2, B2 to either faying surface using a short,stiff bristle brush, spatula or filleting gun. If the gun is used for application, the sealant must: be smoothed with a brush or spatula. b, Cover the entire faying surface with a sealant coat of sufficient thickness (1/32 to 1/'16 inch) to assure extrusion along the edges of the faying surface when the mating parts are assembled. c. Assemble parts immediatelq- after application of sealant, tighten screws to obtain, as near as possible, a metal-to-metal contact. d. After fastener installation, remove the extruded sedia~rt from the wing surface. REVISED JULY1980 7-7 Island Enterprises 3. Sealing ~rocedure (for wing tank access panels other than wing-walk panels). a. Apply a coat of 3R1403-G-~2 to either faying surface using a stiff, short bristle brush, be a spatula, or filleting gun. If a gun is used for application, the sealant, must smoothed with a brush or ssatula. b. Cover the entire faying surface with a sealant coat of sufficient thickness (1/32 to 1/16 inch) to assure extrusion along the edges of the faying surface when the mating parts are assembled. c. Assemble parts immediately after application of sealant; tighten screws to obtain as near as possible a metal-to-metal contact. d. After fastener installation, remove the extruded sealant from the wing surface. 5. Description of Leaks. It is important to make careful periodic fuel tank inspections. These inspections are particularly important in co~fined areas of the airplane which are not exposed to air stream in flight. Classification of fuel leaks, which occur in both confined areas and open areas, is necessnrv to differentiate between those leaks which require repair be- fore flight and those which do not constitute a flight hazard. The wetted area around a leak is an indication of the intensity of the leak. All leaks should be mar~ed and the location and intensity of the leak should be recorded. a. Classification of Leaks as to Intensity and to Location. 1. Classification as to intensity (See Figure 7-2). a. Stain is a slow fuel seepage which tends to dry as it is exposed to the air. b. Seep: A seep is a fuel leak which reappears in a short period of time after being wiped clean. c. IIeavy seep: A fuel leak which appears immediately after being wiped clean. d. Running leak: A leak which nows steadily. 2. Cbassficationasto Location. of the a. Slow to heavy seeps occurring in open areas, such as the surfaces leaks wing or wheel well which are exposed to the air stream in flight, are which do not constitute a flight hazard. Such leaks need not be repaired before flight, provicling the condition causing the leak cannot result in a leak: of greater intensity after a flight is in progress. Seeps considered permissible for flight should be inspected frequently to see that an increase in tensity has not occurred. b. Leaks which constitute a flight hazard. 1. A leak and any leak in a confined area not exposed to the air stream should be repaired before the next flight. (See Fi~ure 7-3.) 6. Leak Detection. a. External LeakDetectionAfter Fueling. 1. To be able to trace the leak from where it appears on the o~rter boundary to its true source inside the tank, the exact point where the fuel is escaping from the tank must be determined. Locating this point will help determine from which fitting or seam the leak originates. and crevices 2. By usi~ an air gun to blow and evaporate fuel from the seams the tank of the leak area, the exact point where the fuel is escaping from may be more clearly defined. 7-8 REVISED JULY 1980 Island Enterprises FIGURE 7-2 FUEL LEAK CLASSIFICATION DIAGRAM D1A A STAIN i l/t" DtA B-SEEP 4'5"D1A 6" MAX C HEAVY SEEP D RUNNING STAIN AREA WHERE FUEL APPEARS TO FLOW OR RUN FOLLOWING CON- TOUR OF SKIN WHEN THIS AREA IS WIPED DRY. FUEL WILL USUALLY BEGIN TO DRIP AFTER REACHING THIS POINT. 7-9 Island Enterprises FTGURE 7-3 TANK AREAS WHERE FUEL LEAK REMOVE ONLY TOP INSPECTION PLATES TO PERFORM PERMANENT TANK REPAIRS. LEAKS 1N THESE AREAS SHOULD BE REPAIRED BEFORE NEXT FLIGHT. 7-LO Island Enterprises 3. Small seep leaks can be traced with the raw edge of torn paper. The Fuzzy edge of torn paper adsorbs fluid and gives a good visual indication of the presence of any fuel when brought in contact with suspected leak points. 4. After the leak has beentraced to its exterior source and marked, drain fuel from tanks. b. Internal LeakDetection. 1. It is very important that the true source of the ir~terior leak be found in order to make a permanent repair. The fuel tank is a network of seams, and fuel may flow through or along a seam, or from one seamto another and may channel a few inches or several feet to the point where it appears on the external boundary of the tank. 2. Enter the tank thro~h the top inspection plates only (see Figure 7-3) and illspect the sealant in the general area of the o~rtside leak point. Look first for bare seams, rivets, and bolts in difficult-to-seal areas. Inspect sealant for blisters, pin holes, cracks, splits, and loss of adhesion. Mark all flaws with masking tape. 3. Test each flaw inside the tank with 20 to 30 PSIair Cfiltered) line pressure by holding the air nozzle against the flaw and check the o~rtside leak point closely for sjo~s of fuel. 4. After testing allflaws inthis manner, and if no leak source has been dis- covered, apply bubble fluid to outside of tank and again apply air pressure to flaws inside of tank. 5. See Figure 7-4 for suggested method of leak detection when a leak is sus- pected around a rivet or when the above mei~hods have been unsuccessful. 7. Leak Repair Procedure. a. Temporary Repair of Fastener Leaks. 1. Generally all leaks located in enclosed areas and runnino leaks in open areas constitute a flight hazard. Fastener leaks in these categories ma~ be repaired temporarily by the application of a sealant fillet over the fas- tener head on the fuel tank exterior. 2. In order for satisfactory temporary repair of a leak to be made at a fastener, structural integrity must exist in the area of the leak. 3. Temporary repair procedure for fastener leaks. a. Remove sufficient fuelto drop the fuel level below the leak. b. Clean the head of the fastener and the adjacent surface with Turco 657 t~ipesolvent orequivale~t anddrythroughly. Fastenerheadand adjacent met~ must be free)from paint, dirt, and oil. c. Apply 1/8 inch thick coat of PR 1422-B 1/2, B2 or CS3204-B 1/2, B2 over the head and around the fastener. d. Cure the sealant untilfirm and rubbery. e. Refillthe tombs and carefully examine the repair periodically. If leak reoccurs, remove the sealant and either make a new temporary repair or make a permanent repair. REVISED JULY 1980 7-11 Island Enterprises b. Permanent LeakRepair. 1. If the leak source is determined to be around a rivet or threaded fastener, the repair procedure shall be to restriki the rivet or retorque the fastener to the maximum torque valve permitted. Any rivet can be resttck only once. If the leak continues, the rivet must be replaced. Repair any sealant damage due to the restriking or retorquing operation. 2. Remove sealant in immediate area of leak source using a sharp non-metalic tool; a chisel-shaped formica tool is suggested. Bevel or slope end ends of existing sealant so that the new sealant canform a continuous and smooth tie-in. 3. Thoroughly clean repair area using a metal cleaning solventto allowgood adhesion. Wash one small area at a time. Then dry with a clean cloth before the solvent evaporates to prevent redisposition of oil and dirt on the surface. Always pour the solvent on the washing cloth to prevent contamination of the solvent supply. 4. Cleaned area must be thoroughly dried by blowing filtered air over the im- mediate area until there is no possibility of solvent or fuel entrapment under adjacent sealant. 5. Apply sealant as required for repair (See Figure 7-1). Repaired fillets must be blended into existing fillets and worked with a filleting tool as required. 6. Allow all repaired sealant to cure to, a tack-free condition, and apply two brush coats of PR 1005-L to the repaired area. 7. Recheck for leaks by applyinp; a coating of Turco leak detector to the outside of the sealed tank with the rank cap and vent closed as the tank is pressure tested with 2 psi of filtered air for a minimum of 30 minutes. Do not exceed 2 psi pressure. Leaks uiill-be indicated by the presence of bubbles in the Turco leak detector. FIGURE 7-4 FUEL TANK LEAK DETECTION DIAGRAM INTERIOR OF TANK j C3 t-J LEAK SOURCE NOTE: i. USE THIS METHOD WHEN rch V~ LEAK EXIT _ LEAK IS AT RIVET OR SCREW. 2. PAINT THE SUSPECTED AREA ON THE INSIDE OF THE TANK WITH BUBBLE FLUID. REMOVE TRACES OF FUEL BEFORE ALL II AIR HOSE APPLYING FLUID. MAX PRESSURE OF 10PSI 7-12 Island Enterprises SECTION ELECTRICAL SYSTEM Island Enterprises SECTION VIII ELECTRICAL SYSTEM A. GE~RAL The M 20 series aircraft have a 12-volt electrical system. A 50-amp, heavy-duty generator provides adequate current so that, even when high electrical loads are placed on the system by multiple radios, 33- will remain at full a rotating beacon, and navigational lights, the heavy-duty or 35··amp battery Charge. The 1962 M20C is eedpped with a 33-amp battery. side of the firewalI. The circuit The battery on the M20C and D is located at the forward left-hand breakers, designed to relieve the electrical system of any over-loads, are located on the lower ri~ht- hand side of the co-pilot's instrument panel. ThebatteryontheMzoE&F Is located aft of the baggage compartment and is accessible through the radio access door. of the instrument The master switch for the electrical system is located at the top I~ft-hand side panel. B. TROUBL~ SHOOTING Malfunctions peculiar to the electrical system are listed in Table 6 along with their causes and sug- pested remedies. When trouble shooting, check from the power supplyto the item affected. If no trouble is found by this method, the trouble probably exists inside an individual piece of ec[uipment known to be which may then be removed from the airplane and an identical unit or units, tested and good. installed in its place. I. ElectricalSwitches andCircuitBreakers. Electrical switches and circuit breakers, located in the lower left and lower right instrument panels, control the navigation and instrument lights, landing light, electric turn-and-bank indi- cator, electric fuel pump, and other electrical components. The circuit breakers automatically break the electrical circuit if an overload is applied to the system, thus preventing damage to the electrical wiring. To reset the circuit breakers, simplypushinthebuttons. Allowsuf- ficient time for cooling before resetting circuit breakers. When a circuit breaker has tripped a second successive rime, the cause of the overload should be determined prior to attempting to reset the circuit breaker. 2. Battery. The battery should be maintained in a fully charged condition at all times, and the water level should be checked at regular intervals; never add anything but distilled water. Do not overfill as the electrolite will overflow and corrode the belly of the airplane. A hydrometer check should be performed periodically to determine the percent of charge presentin the battery (Refer to Table 5~. A fully charged battery will not freeze. All connections must be kept clean and tight. If the battery is not uD to normal charge, recharge, starting with a rate of four amperes and fin- ishing with two amperes. When cleaning the battery care must be exercised to avoid contamina- tion of the electrolyte. REVISED NOVEMBER 1966 8-1 Island Enterprises NOTE: Quick charges are not recommended. 3. Battery ChargingSystem. The charging rate of the battery depends upon the condition of the battery and the voltage regu- lator setting. With all loads off and the engine running at 2000 rpm or higher, the normal battery charging rate will be 5 to 35 amperes. if the charging current is considered excessive, check the following: a. Charging rate should slowly drop to 10 amperes or less after 15 to 20 minutes of flight. NOTE: A very low battery will take longer to show a drop in charging current. b. Too high a voltage regulator setting will cause excessive heating and loss of water. NOTE: Measure the voltage with a voltmeter at "Batt" terminal of the voltage regulator. At 800 F., the voltage should be 13.8 to 14.8. This voltagewill behigher if the temperature is less than 80" F, and loner if the temperature is higher than 80" F. If charging rate is low, check the following: a. The charging rate of a fully charged battery is normally from 1 to 4 amperes. b. The regulator should not be considered defective because ofalowchargingrateuntil: i. A voltmeter check indicates that the voltage at the''Batt" terminal is below require- ments given in NOTE above. 2. A hydrometer check of the battery indicates that the battery is not fully charged. Refer to Table 5 for hydrometer reading vs. battery charge percent. 4. Voltage Regulator. See Figure 8-1 for voltage and gap settings. SHOP NOTES 8-2 Island Enterprises TaBLE 5 HYDROMETER READING VS. BATTERY CHARGE PERCENT Hydrometer Reading Percent of Qlarge 1280 I00 1250 '15 1220 50 1190 25 1160 Very little useful capacity 1130 or below I)ischarged Based on battery electrolyte temperature of 80" F. If battery electrolyte temperature is below 80 F, subtract 4 points from the hydrometer reading for every 10" F below 805 F. If the battery acid temperature is above 80" F, add 4 points to the hydrometer reading for every 10" f- above 80" F Example: Hydrometerreading (1260) Battery electrolyte temperature (300F) Subtract 300 from 800 500 (5 x 4 20) Correct reading (1260 20 1240) SHOP NOTES 8-3 Island Enterprises FIGURE 8-1 VOLTAGE REGULATOR SETTING CHART f o CUTOUT RELAY VOLTAGE O: REGULATOR CURRREGULATOR #1119224 DELCO REMY ~OLTAGE REGULATOR GAP SETTINGS CUTOUT RELAY VOLTAGE REGU`LATOR CURRENT REGULATOR AIR POENT CMSMG AIR AIR GAP OPENING VOLTAGE GAP GAP ,020 .020 11.8-13.5 .075 .075 8-4 Island Enterprises TABLE 6 ELECTRICAL SYSTEM TROU BLE SHOOTING BATTERY TROUBLE CAUSE REMEDY Discharged battery. Battery worn out. Replace battery. Char~n,o rate not set Reset (Refer Lycoming Manual). right. Remove load when generator is not Dischar~ng rate too great. charging and reduce use of starter, II etc.. on ground; use external power whenever possible. Remove and II Standing too long. recharge battery. left on Equipment Remove and recharge battery. II accidentally. in a Impurities electrolyte. Replace battery. Short circuit in (ground) Check II wiring. wiring. II Broken cell partitions. Replace battery. Battery life is short. Insufficient electrolyte. Maintain electrolyte level. Remove loads when 11 Heavy discharge. generator is not charging. slow for 60-100 hours at II Sulfation due to disuse. Long charge 1/2 regular charging rate. II Impurities in electrolyte. Replace battery. II Low charging rate. Adjust voltage regulator. Cracked cell jars. Hold-down bracket loose. Replace battery and tighten. II Frozen battery. Replace battery. of Compound on top Charging rate too high. Reduce charging rate by adjusting battery melts. voltage regulator. Too much water added to Elecrrolyre runs out of Drain and keep at proper level and banery and charging rare vent plugs. adjust voltage re~lator. too high. Forr~ision inzide from Spillage overfilling. Use care in adding water. Vent lines leaking or Repair or clean. ii clogged. 8-5 Island Enterprises TABLE 6 (Continved) TROUBLE CAUSE RE;MEDY Adjust II Charging rate too high. voltage regulator. Battery freezes. Discharged battery. Replace battery. Water added and battery Always recharge battery for 1/2 hour freez- not charged immediately. following addition of water in II int weather. Leaking battery case. Frozen. Replace battery. Battery polarity reversed. Connected backwards on Battery should be slowly discharged airplane or charger. completely and then charged correct- ly and tested. Batteryconsumes excessive Charging ratetoohigfi. I Correct charging rate. water tin all cells). Battery consumes excessive Cracked jar. Replace battery. water tone cell orily). GENERATOR within If the is low, Generator operating voltage gen- Check for loose or high-resistance con- resi- rated speed range but volt- erator is operating on ,,ti,ns; clean and tighten. age output low. dual magnetism. and all electrical con- Loose or high-resistance Clean tighten II electrical connections. nections. down Brushes excessively worn. When brush wears to 1/2 inch, replace with new one. II Caution: Do not use abrasives of any description in seating brushes. Brushes binding in the The brushes should be a free fit with- brush box, out excessive side play in the brush boxes. Bindingbrushes andbrushbox- II es should be wiped clean with a cloth moistened in Varsol or unleaded gas- oline. Excessive side play of Replace the brushes as outlined above. II brushes in brush box. Brushes not properly Reseat brushes as outlined above. II seated. Low brush spring tension. Brush spring should bear centrally on top of the brushes, insuring full brush II contact with the face of the commuta- tors. with cloth mois- Dirty commutztor. Clean the commutator a II tened in Varsol or unleaded gasoline. Island Enterprises TABLE 6 (Continved) TROUBLE CAUSE REMEDY Scored or pitted Turn down commutator or replace. II commutator. Shorted or open armature 11 cells, Replace renerator or armature, Improper operation of Adjust regulator or replace. II voltage regulzcor. Generator operating with- properly See electrical in rated speed range but system wiring diagram, voltmeter indicates zero. Unstable operation of the Replace Use voltaoe re~ilator. Same voltage regulator. remedy Ceneracar operating with- under "Generator operating within rated as "CeneraEor operating in rated speed range, but speed but low, within rated speed range voltage output voltage output is erratic. range above. but voltage output low", above. Excessive at Same as "Generator sparking oper- Use remedy under "Generator oper- brushes. within rated speed generator ating ating within rated speed range but volt- but range voltage output age,,tput low". low." above. Generator oiDerating with- Generator field marm~t- Flash field with a jumper wire on in rated speed range but ized in the wrong direc- regulator'between generator and bat- system ammeter or load- tion. tery. meter reads off scale. ammeter fluctuates Check the for abnormal loads. System iS system ercessively when indicat- ing full rated load. lm_oroper operation of Readjust to operate properly. II generator reverse-cur- rent relay. II Loose connections, Tighten connections. with Burned-out system Discharged battery. Replace fully charged battery. Re- Defect~ive all defective ammeter or line fuse. wiring. Replace wiring. STARTER LOW if Motor fails to operate. battery charge. Check and recharge necessary. Defective or improper wir- Refer to electrical and ii wiring diagram ing or loose connections. check all wiring. Defective starter solenoid Replace faulty unit. or control switch. 8-7 Island Enterprises TABLE 6 (Continued) TROUBLE CAUSE I RE~EDY Binding, worn, or improp- Brushes should be a free fit in the erly seated brush, or brush boxes without excessive sideplay. brushes with excessive Binding brushes and brush boxes should side play, be wiped clean with a gasoline-mois- tened cloth. A new brush should be run-in ~nril at least 50~ seated; how- ever, if iscilities are not available for running-in brushes, then the brush should be properly seated by inserting a strip of No. .0000 sandpaper between the brush and commutator, with Sanded side next to brush, Pun sandpaper in the direction of rotation, being careful to keen it in the same contour as the com- mutator. Caution: Do not use coarse sandpaper or emery cloth. After seating, clean thoroughly to remove all sand and metal particles to prevent excessive wear. Keep motorbearingfreefrom sand or metal panicles. Dirty commutator. If commutator is rough or dirty, smooth and polish with ~0000 sandpaper. If too II rough and pitted, remove and Nm down. Blow out all particles. Shorted,grounded, or Remove and replace with an armature II open armature. known to be in,aood condition. Grounded or open field Test and repair if possible or replace circuit. with a new pan. Low motor and cranking Worn, rough, or improp- Disassemble, clean, inspect, and re- speed. erly lubricated motor or lubricate, replacing ball bearing if starter gearing. worn. Same electrical causes as fails Same remedies listed for those mal- II listed under "Motor functions. to operate". Binding, worn, or improp- Excessive arcing of motor -erly seated brush or See information above dealing with this brushes. brushes with excessive malfunction. side play. pitted, or Dirty, rough, Clean as outlined above. II scored commutator. Remove and turn down Excessive wear and arcing Rough or scored commutator on lathe. of motor brushes. commutator, Armature assembly not II Reface commutator. concentric. 8-8 Island Enterprises TABLE 6 (Conrinvedj ELECTRIC GEAR TROUBLE CAUSE REMEDY Bulb burned out in red Gear will retract but red indicator light. Broken Replace burned out bulb. Check indi- indicator light (press-to- wire in indicator-light cato'-light circuit and/or the down- rest) ~cill not show. circuit. Up-limitswitch limit switch. inoperative. Incomplete Retraction- Bind in gear retraction Refer to Section V for landing gear Gear retracts to an inter- system because gear is rigging proceduredescription. Examine mediate position and out of rig. Malfunction all movable retraction system pans stops short, in gear electrical cir- for proper lubricaiion and freedomfrom cult, inoperative actu- binding. Check for actuator worm gear ating motor, or weak binding and lubricate as needed. Any battery. malfunction can cause the 2S-amp land- ing gear circuit breaker to trip. Check gear electrical circuit for loose con- nections, broken wires, or defective relay switches. Recharge battery if necessary. Gear will not retract at Insufficient airspeed, Check pitot tube and line for obstruc- or above 80 mph IAs pressure switch inoper- tions. Examine switch for (M20C~. pressure ative, or circuit breaker adjustment and Reset Gear will not retract at or proper operation. tripped, circuit breaker. above 70 mph IAS (M20E F~ Bulb burned out in green Gear will extend but green Brokenwire Replace burned out bulb. Check indi- indicator indicatorlight. light (press-to- i,indicator-light circuit. cator-light circuit and/or the down- will not show. limit switch. test) Down-limit switch is inop- erative. Actuatmg motor extends Same causes as listed with Same remedies as listed with "Incom- to an intermediate "Incomplete Retraction" gear above. a'oove. plete Retraction" position andstops. Actuating motor will not Same causes as listed with Same remedies as listed with "Incom- initiate extension. "Incomplete Retraction" plete Retraction" above. Also, check above. circuit breaker. Gear will extend manually Gear switch is not in down Place switch in down but green indicator light gear position. Bulbburnedout burned out bulb. (press-to-test) will not position. Replace in indicator show. green light. Manual cranking will not Drive-connector is out of Adjust control-cable tension at drive- lower gear. rig. Sheared female spline I connector lever. Replacedrive-connec- in drive-connector. tor assembly if female spline is stripped. REVISED NOVEMBER 1966 8-9 Island Enterprises SHOP NOTES 8-10 Island Enterprises FIGIIRF 11-7 F1 ~r7Rlrdl ~YSTEM DIAGRAM (1962 M20C S/N 1910-2296: CII1C(IIT r-----^ Urlll~KtnS -·11--(11 II r _J -15 sc -I SWITCI~ GEAR WARNING PL~.(nLI VI.)IIJIC PAOBE a* hz_ SWI~CII (~1(1 urttc~on) a*rt VII(H~ INDICA1OR -I RADIO -16E --IG c*nu *la trur. sp_ (YT )10(t: I -164 am (6 RADIO -174 I\ADIO Smal(ER OPT AAMO GENE)IATOR SWITCI( ~16111) I IwlfCII )i)ltllOL1 VI~RHIIIO·Pe.· a INOICATO[)-IUns( L IllnolrLE IlORN LICIITS v.laao -19 or*n ~e v O R LIGIIT LIGI IT IQ 11, 79 cr*n IQRIIII(O sr*n H*nlllao -IW A -111 SWITCI( VOLTAGE InOlCAtdl UOlll) P-o ~24. LAMP I.AMP REGVLI\TOR r VACUUM SWITCII r(l( IIIIC(n~ ~0111*9 S)(UNT c ~u,o I·aot ~Z 1 87 2L FUSE ,o* CIGAR LIGIITER -I ~s L_1 L1-.1 -1....- --I----·---- I I L-----l t PnOBE ~a- rugql -119 -:1--161)-·-111 --110 GUAGE -169 MASTER _BB hhC~IC-is7 SWITCH 3' -i33111 n~ m BVLB U- OILTI)(P .68 -120 --117 -121 ·-138' ~ANDING 1 LIGHT MAGKTO 44 Alc,n SWITCH IOltlOH (laR~ LIGI-(T ASSEMBLY worrlp) ulaG, bALEH rvr~ MnoNiTo .p _I I-_LI 1-1 -152 -142-111 LQL 12L )3 LEII a '0" 4~? 81 ASSEMBLY 64 TAIL CIGI1T 82 5* 62 ~h --5-O~ol'' IssinRrER sus om VIBRATOR lo* -12~7 Xt loruws oEloac-oPr 90 -Ino~lllu LIGHT ASSEMBLY se lo~ VIHG~RLD r TERY U C 40 65 PITOT g~e ELtCrRIC OPIIOHIC STARTER POWEII~ a ~VtL PU)b SOLENOID RELAY I ISTI. ALLjTEM NUMBERS ARE UNDERLINED (REFER TO ELECTRICAL EQUIPMENTIsland Enterprises 220U, 2256. 22Y/ tlrru 262L) ft~UKt: ~·j II~LECTRICAL SYSTEM DIAGRAM (1963 M20C S/N cmcu-r _22 (llctlllcCONNEC~:nG ungAKE"5 II m -(II t; swl rcle enOOE GSAFI WAI1NIFIG mt-~ulL SWITCII (Ilr1 Dltl~Jnn) -I UrE l110111(1*11 VIRH~ volc~nlon c*ns llla 1I)(P~'. ~lm MPIO -K;4LI. Ss 1'12-·----(11 csaE ,core ,6) 04010 T ss nADIO -jg "1 =T~E OPT AADIO SMAKER GENER~TOR QR -143--~21-152 SWITCI( --Hsf)n~oo*L i* LKJI1)J LWILII )I~1L)INI c~*n wAnlllna- (a*la L rllnortLE II HOAN 1.101175 oLln Wlnmlld -14 4 ----,t-- 40----~-- -49 -51 (i R t LIGHT UZ LIGIIT '----53-·0:as ec*n v*nllllla sl*n HlnlllllO VOLTAGE SWITCI~ Bq 11)01C110n REGULATOR TZ. m ~95. LAMP LAMP VACUVM SWITCII TUIL ~ILCC1OA COIIFII~ -II1------~. SHUNT +-----·-113------1---1 1\\ c ruto PILO1 z. nDOTtLD LIHSB IIIDICATE I~EMS USED 01( II1M2OCIJ 82 FUSE ~o* 91711 SERUL 11111122112 I CIGAR LIGIITER 22011,2229 AWll 1297 I I I I L----l-----l------l _ TIIIIWGII 21211 O)(LY~ --I Pnoea FU5E9i~ nLIlECTlYE BEIII*L WULI- CIL. (ILID ILHR -119 -139--111 OEnS -IOB --110 I------~--fl I /F"O V 'I la~a, 1 I -!09 I I IslusTEn GUMIE .na_ SWITCII 2 -1331)1 u_ -11 -Ilo------l 1~------' I 137---1)--1 CANDING- -130 Y I LIGHT HAGNETO -124 1 -69 -71 ~9. ap~r SWITCII I(IHIIIDH (I1*1I1 LIGIIT I\SSENOLY HOIC IF) O*UGL VI.1 wlllsl cPrca reci 1*)1*·116111 MAONETO -152 -142--11~ LPL L?L LcEt B -b~· B 102 f~. I I I _i_l_ 811 IY-i~'O" r, W '~-91-----J TAIL LIGHT ASSEMRLY 3-'6~7 8~ 5~ --60·------7~- ~R nl SlnRltR YIBR1IOR S ~I· 59 Ina----O·j~-(l' nOmlNGDE*Cal-OP~ I I -141 T )55 LIGHT I\SSEMBLY 4s_ ,-93--~1)-1_3'1 H1110I RCO TER~ 42 65 ··-~f-'l PITOT B100 OPIIOHLL 4 lLlCrnlC STAAIER WWER a4 iVCL PUIIP SOLENOID RELAY ~j-jt731'2-lool NOTE: 4LL ITEM NUMBERS ARE UNDERLINED (REFER TO ELECTRICAL EQUIPMENT LIST). Island Enterprises 101-200) FIGURE 8-4 ELECTRICAC SYSfEM DIAGRAM (1963 MZOD S/H CONNECTOA r------ll (LLe~ale rLVC Sil -149 ---~2-- 07----0-- -154 B 5WllCll 92. Pnoec: GEAR WARNING rllT·IrILL Wlnllllll I DL1IClOn) SWlrCI~ Z1L (Llr E rLlall~ (I~IWA1 c~nl rtn IIHP. B9 I"`~". 1 r -IGs IIIII (nrrl (IEB l(OTE Il) I RADIO T @2 nADIO SPLAHEFI -jg "1 OPT IIAMO GENERATOR SWITC)I u LICII1II~HIICII US[)IBL* VJ6 L ~I HORN LlO)lfS -51 dLlk WlnlBl(O 78 ·I-Is NliT~ *L.lllllr( a R LIGIIT I.lGlIT -U-0'---111 ct·cl~ v~nllllco la sr*n v~nlllllo SWITCII VOLTAGE GEAR RLTAACTMN SYSTEM I)IPICIIOI 8~ ~IXL LAMP LAMP REGULATOR i 72 .1-~)9I vAcUUM SWITCI( rULL IL~CCIOR COI(P*II 11110 P1101 -111 SHUNT 'I L D HO.~I IVITCH -I(( ,oA -I 9 V1RL( V1LO MI HtOO~l VIIH oub IIIII L~o-l )IUHtltn( 1 1110 101 87 tl~nousll Ico OHLI. 91. FUSE clonn LICI~TER 69 -I PROBE 1Q crusEg2 crl.II(*D IL~P. -119 -139-111 -100 --110 cvAae -159 1 IcumEn _86_ SWIIC)1 -131------133111 O~LVILLIIP h~i 1L --II --138 LI\NDING LIGHT MAGNTO -124 -69 44 bIWlr -I_ SWITC)1 IONI~IOH (IBR1 LIGHT ASSEMBLY m)lEIP) wlwc, cnrrH I*ll*·abH1 U40NETO -142--(11 H19L 1ZL I LI '-I ---1_1 102 81 '0" TAIL ~IGI1T ASSEMBLY -li5-- -e3. =S-;l,-16 -I -64------1)------r BZ "5 -6t 46 -·-c~r HOTCO) OUI (SLE '01 vlonaron 50 -127 ROIUIWS DELLIW-OPI ~--1 XI -141-~>--93--'>..94tlu LIGHT ASSEMBLY IOI ulnG,RED ~Y TERY M9 PITOT r;IOQ 42 65 ELCCIAIC OPIIONI~ 4 PV"P STAFCTER POWER a~ 3) -le4-~,)--J'VEL SOLENOID 1·· Island Enterprises ·III~· CIRCIIIT IICtlRICCONNEC!I)IG I I)(IF~nKERS _2_4 -I-171 -)5j P Il--rPnoeE 9 GEAR WAR~·IING SWITCI( SWITC)I 22 INDlr,ATOA LV*nH~ e~ns ~ln tt~tr. -141 qe (Icr ,lotrldj -152---(11 -39 -164r~ll RAGIG ,,,r OPT RAMO I~hDIO SPEAKER SWITC)I -145---"1)-- 3.GENERATOA!k 25 r* -170-111 "C::I8~o' INDICATO~n-IUnl( (a~ln OO"E Iloll~, I WI1EII I~)tlll)L1 -52-~-----111 I~nnN VJC cLlkkiiiinso -so-----tt------3~/ll ~UL -40 R Lii-~144 ~---19 Ilr.llT LIGH1' (I tr*nWlnlilll~ae n .__ I~ -53 -161 -f~3.ti---111 VOLTAGE REGULATOR 10" .r gp SWITCI( .7it se at ~10111) LAMP VACVUM SWITCI( LAMP -III C-;IUNT 1 ,111 -1]2 rVtLSLILCfO. tollnlr L ruto FILO1 n -1 ,9L 97 LZ~-l. 69 CIGI\R LICI(TER -1 Pnoee lg -1 CIL.1ILIO 1L)III ruse 9Z -100 ~"9_1 1 --110 -ltis SMWAISTTCE~ GUhOE Ue -II L~NDING- -1 LIGHT MACNETO 38 14 -124 Y "cHr ,I_I_I, -108 (--I -69 -150 SWITC~1 lBHlllON (~aRI MAOMTO Holr19) LIGHT ASSEMBLY HIHG) GRtEH UrT G*UGF~! ,F!IQL NIL ~ol -64·----~------cj I I I ·Is atru r,TAIL LIGHT ASSEHMY SIAR'IER VIBnl\TOn x, -140-----f~I·J(I [_. IOII1IWb BEICCXCOT~ ~tl LIGHT ASSEMOLY _42 I 1 65 ··-~i-'TERY loA. 199 HlllO,nCO ncRl eH PITOT 8 POWER 4 OPIIOH*I. SOLCNOID RELAY 108 ALL NOTE: ITEM NLJMB~RS ARE UNDERLINED (REFER TO ELECTRICAL EQUIPMENT LIST). Island Enterprises FIGURE 8-6 ELECTRICAL SYSTEM DIAGRAM (1961 M20C S/N 2657 thru 2741; 2743 thru 2806) OIIICUIT I!Ht~l\tnS CONNECTDF( clrctnle PLUL ---- z -le-·2. 1~61-I· 49 1l1 co~ ?I F115E CIGAI~ LIGIITER i L._,,,~ -206 Pnoec: 1P- -211 CILIII*D I(HP. I 1-- -IE9 NASTEA "CO~' -IOI--C swlrcll IJI CONNECTOR st ~lrt·-i -IUII( 11I ol~aHp .u. I 1!1 I- ~I ·I -210 1' -121 -207 ~F,cuKnR GAUGE LA~IONG -213 LIGHT HbSINTO -rjtf_ uun I~G 7/ SWITCHloHl~loH 1 11~11 --IE·l LIGHT ASSEMDLY HOt(lO) 6RI(H UII V1HCI NIL WnGNETO ggl ss Irc·r -142--111 B 19L PIPL~1L PI lo* Y -64 -91 TAIL LIGHT ASSEMBLY 45 a~ 119 B_ -Ipe vil~aUilR 10* -140------0~)11 -8~;-111 nor*rull OEILO~·OPI T1 03 se _94---f_l LIGHT ASSEMBLY 10* VU(G,RED 42- 65 TERV t; 1 1· 1 !49 PITOT STAF(TER POh'EII 4 ~LLCIRIC OPrlOn*L iuri UHP SOLCNOIO MLm !s~ C3-3r- Island Enterprises FIGURE 8-7 ELEC'I'RICAL SYSTEM DIAGRAM (1964 M20D S/N 202 tliru 251) CONNEC3~th --17 UAEAHLRS 9 SWITCI1 GEAR WI\RNING rRr-,u~l hZ SWITC)( (Ll~f DEILC1OR) CI1)WRIIOR )LTI ILIOII~(ITILL V*~H) RAP!Q\ _,,, -(gc?-~ll -154---7-164 worC eoooV_lI BW s*R (I~) 16~ jiP.Lbl9 RAMO SPEAKER -jg ss ,--rt: OPT nnMO SWITCII ZB PM(L L1OII~I 1 LVIIR( INDICATOnJUnH I s~a* L rltnornr GENEII~TORHOnN ---157---1>------LIGHTS YIAHIIIO ZP r~ocL A(UHOLIO r )A O R I LIGHT LIG~(T (ILUI Iq. -Uo"--, OLIR ~RWIIIO W11\1(11(0 -167 ITT~'i)--···r~-·- CEAR RETRACTION SYSTEM OPTldHAL OH M 20 D SWITCH 60 eolc~rol LIGI)I: I :tL ~9U. LAMP LAMP ~1I VACUUM SWITC)I TULL 1ELLC~OR COIUYU -I S~IUNT *uro PIIOT -IJ·I ~Z lo~ ~tB 91 FusE 81 CIGAR LIGIITER 69 206 -206 PnouE 3e F~)5E q2 -211 _ 49 -16Y MASTER .1. SWITCH DULO GZ -133111 i. CONNECTOR UIL rEHP 69 7L -210------~---- -207 CLUSTER L·u_LANDING--~ -206 GAUGE `1 75ft 94 1 -124 I- LIGHT ASSEMBLY HO~C 19) ;3\ MA(INETO VIHCI ORI~H LLfr LPL 93· 43 -142--111 l9L 109 81 lo* t -64------~------,, TAIL LIGHT ASSEHBLV st at Fi.~ S'IAIITER VIBRs;lOR -la7 lo* POTIIUt6 BC40H-M1 I----1)-- 4e LIGHTASSEMBLY _II r;s TEAY VWO,RCD ~9 PITOT STARSEI\ POWER 6 OPOOH*L MI.EN(~, RELAY 109 -MI I:::LC`bH~CHp NOTE: ALL ITEM NUMBERS ARE UNDERLINED (REFER TO ELECTRICAL EQUIPME Island Enterprises FIGURE 8-8 ELECTnlCAL SYSTEM DIAGRAM (1964 M20E S/N 104 thru 230 rS/N 101 fkru 103 differs only in minor Jetails_J) CIRCUIT CONNECTOR cll(lnle UllrKERS ysn --171 -149 01-----~2-- \---~;--fc- I F~o e SWI1C)I PROOE GEl\fl WARNING 2~ JI Pnl·I1~LL Vlnlll[(( ~t SWITCII (llT1 DC1[Cltl)ll ,*re v*nlc.) INOIQTOR 1L ~ln tlllP· -197 eP ~I 1 4,, -192---111 -IOe -IG4 (ui wolrlb hAt)lObo 105 T -14ti------O -)-t t- RADIO -39 "1 as EOPT RADIO Sl'EAHER O (iENEnAfOn ee sw(rol -199 Iwlrcll cr~k w*nlllllc- INDiCi~TOllausl (o~lla ~llnot ILL .j: IcnnN aa*iikiii8,to LIGl(fS I -144-----~--- -40-----~-- -49 -51 FIILL *5I[1(1111) 0) I 'A LIO~IT Ig LIGHT oc*n v*nlllllo ~L*n Hlnl(ll(O ·jl~ L9 -U-O~kc, -167 dl VOLTAGE 5WITCI( IGO-111 80 Clllllt) REGULATOR I ~se 'L--'r"lD'F*'O" LAMP LAMP VACUUM SWITCI~ rUCL ILLLCIDI COI(IXII -III------~ B(VNT ~------115------1-----·1 1\\ c ~ulo PICO1 z g 154 81 FUSE ~0* 91 CIGAR LIGHTER 1 I 1 1P. -175 I I -108 --110 lr -169 MASTER culiaE b~( -181-4 SWITCI~ -195 -133111 ouLe m on ICI(P ha U- -ILO -lal I L------' -I LANDING 80 CIOHT MAGNETO 40 RIWIT -63 SWITCH -150 laH(TIOH (llliR7 LIGHT ASSEMDLY OUIMII blV6CMT HOIC~P) CAI(H WlaG, NI~ -152------J9.? 113 -142--111 B -6··Irn LZL 102 81 lo* -64------~------gl------I TAIL LIGHT ASSE~BY -215 15 Bi: 60~-61--1)---62 8·· 202 57nAIEn ~90 aanarcn -$;-11' -204 ~e nomlllcw*uxc-or~ m v, 14 -)93 -199 491 I.IGHT ASKMBLY WII(O, REO 5 42 I8C;TTERY( 109 PITOT ;2~LOe 4 STARTER POWER 108 rVLL PUHP SOLENOID RELAI K1~ Island Enterprises FIGURE 8-9 ELECTRICAL SYSTEM DIAGRAM (1964 M20E S/N 231 thru J99; 401 thru 469) CIRCUIT 311. cLlc~nle 0"4~KEs SL ec~= -9_ SWITCI1 FEI\R WAREIII(G PnOOF. WIIIIINI tt)H IIHIIHI· SWITC~I -148 i IN~CATOR (L)lt BfllCloR) ElnWmon ,~rr rCIO)I1()IlLL VIRH3 INDICSITOR JL -141 -189 /7tt-_: C/I~ /I1CW)·· tVIDIO Pe (ic( IIO1EI(() -1921-1)1 nAolo U]4i T -29 a OPT nl\MO RAMO SPEAI(ER cEIEnllTon ee SWITCI~ s ZZ LDIII)IIWltell )111[1(8U IND1CATO~1-run,e (s~,tn -199 L (C3LIOI~TS ~---149----1)----IO------1)-- mlxL O P ~r,rHale L(GI1T ELAR WlnlllllO UZ 6ELnL~IO ILL -(61 '1 I VOLTAGE SWITCH Bq II(OIClmA LlOl(tl ~9P 95 LAMP LnMP VACUUM SWITC)( IULI. CO)lr~ll -Ill------C SHUNT *uro Pnol L L~D--h 91 FUS~E 87 CIGAR 48 PROSE -205 ErL~ILIO 1U(F. F 9Z -211 -809 --110 I P,,;nS1T~-- I I -i69 -212---1 SMWn:TTCE~TCI( ht -131 OULO -1JJlll CONNECTOR 48 UL -ZL -210 -207 -208 U\NOWO GAUGE LIO)1T HAG~TO -21$ 1 14WT -108 -150 SWITCH IOHIIIOH ((URI LIGIIT ASSEMBLI' HOICIPI MAOKTO ul~o, cntrs 43- Irr~ -142--1(1 BLQL 43 II I _LL a~ln-ll·· 69-----~----- TAIL LIGHT ASYMBCY BL 0~". ~U ulon*ron i ~z nou~,ns scMFoPr -14 I----t>---SJ-·t)- 42 se. LIGHT ASSEMBLY 65 ul,lc,nro res :-~·dPITOT STARIER ~e POWER OPIIDH*L S(XENO(D rrrc~nle RELAY 4-XII rucL py~p "~IC· "1 I ITEM NUMBERS ARE UNDERLINED (REFER TO ELECTRICAL EQUIPMENT LI Island Enterprises FIGURE 8-10 ELECTRICAL SYSTEM DIAGRAM (1965 M20C S/N 2742, 2807 thru 3184) CIRCUIT .24 CONNECTOR IIRSAKEIIS rlrcInle PLUG ---(t---Il 11-I--- P -154 _9 5W17CH GEAR W~RNINGZZ1 pllr ·ra~ 1 w~ alllpr PROBE 1~1" UlI[ClUIll SWITCH 2Z c~rr r~lP,n(a*LL Mlnlc~ INDICATOR ~U -1 RADIO' -218---1-~---4(6 c~np *IA IIHP. 99 c~----219---111 )101L YDUOII-II UU)LI*n (1\(1) (YL )111 nAOlO -r RADIO SPEAI(ER 99 OPT RADIO -39 98 SWITC)I1. 00)(r LW)ItIL 1 LWI1CII I((~)(BLY r 23. INDICATbR-TuI\Il (u*lln 22·0~--111 L LIG)1TS IlORN rA 61~11 U*11111110 19 -223 223 -i?27 HIIL *(IIHOllr~ I t~LI III LIGIIT LIGIIT 1l1 Iq· cr~n u*cwlao cE*n UUU(IHI 19 i \t9·86; II SWITCII VOLTAGE 94 IIIOIC*IOR LIOIIlI REGULATOR PB 93 LAMP LAMP r), I ~ZL. VACUUM SWITCI( rUrL IrLccIol CDHP*II s)uNT c---·-113------(---1 Ulro PILOT L 82 9L FUSE 'o* CIGAR LK;HTER 89 -206 1- -205 PROBE 2e -211 .·~.,ll·oa*p. L_-LII~E_;?Z__-2"" loo- --1 I- -1 a MASTER -212' -181 SWITCH i ··cD- alllCoNNECroR OILTTHP i IL -uo LI--· -IZI 1LZtLUSTER -208 GAUGE L.ANI)IEIG 213 MaGKTO 1 se Illtl(l -69 I6NI~ION SWITC)1Here LICIIT ASSEMBLY --151------· IF) MI YIHO) CALEH MAGNETO PULL qa -142---111 Ya~· L2L 43_ 81 lo* -64------~-----91------1 TAIL LIGHT ASSEMBLV I I I ss at FlTAnTEn -Ila uBRaTOR '~L -127 98 140--0~-111 X1 nol*rucb DEIMN-OPI ,~lmll LIGHT ASSEMBLY IO* VWG,RED 42_ 1 1 65 ~L4 PITOT S STARTER POWER 4 ILTCIRIC OPIIO)(IL TUCL PU*P 501 tNOII) RELAY L~B t- ,·nsr I I hDE IlhlnFDI IhlFn ~RFFFR Tn FI Fr7Rlr~hl FOIIIPMFNTIsland EnterprisesI I.ST\. FIGURE 0-11 ELECTRICAL SYSTEM DIAGRAM (1365 M20D S/N 252 fhtu 253) CIRCUIT IL(C1IICC~HJNEC3T?R, bl 9 SWITCI( GEAR W~nNING IRC.III PROBE SWITC11 INDICATOR ~8·- ure ILIUI~(IT*LL YUU(~ clla IIR 1IHI· sa 1 IQOP~II1 MI (~tr Here 141 5·INOICAlOn IW]IO 99 RADIO SPEAKER -29 OPT RAMO SWITC)1 22 OOHr LIYI1( 1 LV~IO( I(ILU~LI bC*ll V*RNIH~- INDICATOR-IUw (I~HI 26 L I~ HORIJ Ilh LIGHTS or*n VI)IH110 ~ZB '222 "222 --J>--- -2127 *IfL *IX)(BCYL W(E05TAT LIGIIT LIG)IT ~L (IENCI(ATORU--crARcunlll,olZL U*A WIUHO ~g 3t I, VOLTAGE GEAR RETRACTION SYSTEUL OPTIONAL OII M 20 D 10* SWITCI1 20 IHOICIIOR LIOIII) 12 ~9P 92 LAMP LAMP VACUUM SWITC)( rU~L IFL(C~O)1 CO)(F*L( -III L S)(UNT )----113---1---7 1\\~ II)IOPILO( 3 nlTi~l L--134------1 Pt FUSE co* 9L CIGAR L.IG)(TER ~cD -206 -1Y. PnooE n,SE 92 ··211 CIIIIIEIO IIHP. -N9 --110 -212 -IBI ct" BULB -Iulr CONNECTOR 71. -210 :"':.:I'L"'aq -207 T1Ul~clllslrR -206 OAUBE LAlrDING LIG,1T -213v 1 MnCNIO ;124 qe blW1T -7.1 SWITCI1 I~unloH (Ibu~ LIGHT ASSEMBLY HOrE 19) MnONETO ulHC, ORE(H LLTI laL _42 ~2L IP~ BLI 1*1-1~20* 1 64---1)-- TAIL LIGHT ASSEHBLY 45 82. -6i)-))-- START~R vlenAToR 7 Xt ROWIHb I----1)---93---,t- ss_ LIGHT ASSEMBLY lo* 41 ··~I"· 1 VIHG~ REO PITOT 6~ze SIARSER POWER 4 h10* OPrlOH*L RELAY KPl pUHp NOTE: ALL ITEM NUMBERS ARE UNDERLINED (REFER TO ELECTRICAL EQUIPMENT LIST). Island Enterprises thru FIGURE 8-12 ELECfRICAL SYSTEM DIAGRAM (1')65 MZOE S/N 400, 470 031) CIACUITUnEAKtRS CO(~INECTOR --17 (LtCIAIC -149 --~t- 07--~--. I\- -17 PL61UE Q SWITCH mr·,r*ll wlnl,llto 1/McEnn WARNING (LIT~ OEI(CTO~) PROBE SWITC)I 22. rrw trll,lllo· BZ .LL\ INDICATOR U. 1 RADIO C*RI IIA 1(HC· CI>--2~9----lll QP (XL ItOtCI(I) _Z(Ba, nAOlO pnMo SPEAI(ER T 99 OPT RADIO -39 91J ne CENEII~TOI\ -170---((1uoNr Llbllll *II[(IOLI SWITC)( tr 23. (NDICAtOn-rulac(a~,lle ·a -199 L Miu. LIGI1TS -627 -220-1)- rr,aL ~lnHalrl ~LB -229 -228 ----3)-- -L PZZ d cPl~ijSj/\T``3q 3h_4~1 -O~ill LIGIIT PZ LIG)IT M wwl*o14. 19 98 cr~n VIRIIII(I -~67 II lo* SWITC)( I1IOIC*IOR LIG~I)) VOLTAGE PQ ~qp LAMP LAMP REGULATOR 1Z VACUUM SWITCI( TULL IIL~CIOR CO~PISI 1UrO PICOI -I 5HUNT'. I I ------I -I! BZ 91 FUSE I CIGAR LIGHTER -208 ~i9 -205 -211 PROBE 1P. F 4i~ c·c~. Ilr*o I~HH -209 --110 -a12~---j -169 MASTER SWITCH CONNECTOR Ss_,_~tJ__I,I -IJI·------Ijjlll ill OuLU 62 1L MLIIHP 69 -1 '-210 -207 GAUGE -208 1 I.ANOING -1114 -25 Il(illl H*GKTO 4" .ICHI 1- SWITCH Icnnlon LIGHT ASSENBC' OUU·I·I UHII Ho~rlY) ulnc, cnEEw ML MAGNETO -142--111 FIPL 93~I· Bl2L q3 ur~ 'O* 43 91 TAIL 64 -91----~--1 LIG~IT_ASYMBLY I I 1 82 45STARTER LrS~ A PTn(llEn vun~ran ~e -140 II' AOIIIING ~E*tOH.OPI I---1>- L.GHT ASSEMBLY IOA U~ HWGIRI'D 42 1 1 65 PITOT 6 OPIIO1(IL 4 !P_A 1·1---73--9)--18$~--1 UlL PUHP EQUIPMENT L15T)· I I (TF~( )\IIIMRFRF hilt IINI?L:RI INED [REFER TO ELECTRICAL Island Enterprises FIGURE 8-13 ELECTRICAL SYSTEM DIAGRAM (1966 M20C S/N 3185 tliru 3466) CIRCUIT CONNECTOR ------173------rtlCTRIC URSAKLR'J -249--t)-- 01----)t-- ---F~t··-li 89 P~C .9 rc~l 5W1TC)( 29 PIIOCIE GEAR WI\RNINO i pnr-rTllI WIR(III(( 1EHR 1E1111)10- SWITCI( -240 INMCATOII (LlrT UElrLIOA) c~nwnuon ~Z 2Z r*rr rLserIlr*IL YIIIH.J lseE WOTE 331 INDICATOA U --197 nAOIO -210----L9)---216 qp 119 -----111 ooaal-ll eu, Run ("E 1(01( 31) RADIO T RAMo SPEAKER -39 99 OPT RAWO L- GENEIIATOR P& -143----~-- SWI'ICH -170----111ooHr LIGIII) (IU(ltll IUEHOLY -230 -f;i~ ''II d INoICATOR-TuNl (eAsl L v~ ImnN LIGHTS WH*IIO pllii ~ZB --~----2111 -----1>---234 -21-----~Y NH(L AII(HYIO R O -2 '23"~ ;ih LIG)IT LIGHT )ABWITCI1 ~-L, U1 bTIR H*HIIIIIO L9 -2~ae co* )~Oc--L(II VOLTAGE 612·Ir I\EGULATOR 8e .r ~ZZ. 31 LAMP LAMP IULL (ILICI(IR COHPIII 12L~ -202 S~IUNT *uro IILDT -230 z 54 128 d so* 48 W01211 82 acu~i" I ,o* LICI1TER-2)6t)--L111 CIGAR 1-237 INSII~UMENT PANEL I'OS1 L1O"TS Pnonr Ila. FUS~92 I CIL~IILID TEI(R -200---111 CLUST~R -110 -19 MASTER -IOI SW1T CII -IIIFONNE ou.u BZ OIL~T)IP ~P 1L -C? -210 300 -212 L,~NDING LIGHT MAGNTO -123 _d, _,a ~t RIGHT -188 tu -j~ SWITC11lo,~lnol( rr*RI C worra)' LIGHT ASSEMBLY -280 ulsc, cnrcH MAONETO -I- I~L LEIT -142--111 1ZL II -2TO 81 '0* I~------200 Io -64 ------1>---~ -91 TAIL LIGHT ASSYs.BLY 82 I JZL -sl--1>-- 02-,>- -28~ -28 r 124 -285 STARTER -274 122 4·_ VIORATOR ~fL DE*cac-oPr -126 141 ----~---gj----t)-Rowwc LIGHT ASSEMBLY HUIO, RED 42_ bS 189 PITOT Isre OPIIOWIL STARTER li~3. WWER 4 1~B SOLENOLD RELAY NOTE: ALL ITEM NUMBERS ARE UNDERLINED (REFER TO ELECTRICAL EQUIPMENT LIST). Island Enterprises FIGURE 8-14 ELECTRICAL SYSTEM DIAGRAM (1966 M20D S/N 260 8,ON) CIRCUIT Unrl(ER5 LL(C1AICCONNECTIIURe 117 I swl~ol PROOE W PLI·II*LL UL~(LIOI)) In rrllw (rllll)lP· Et (Llrl C*ROUIIIIOII 22, -211 m r*rr ~LIOIII(IULL u*n,c.) (6EE NOTE Sq) 13 INDICATOR CIAOIIHrEHII RADIO' 2 99 -?ls ---le o PVI .II! CNI) (ILTHOILII) RADIO m RADIO SPEAKER x 99 OPT RADIO ,1 t~ m cerann ;0 LLIIII( IV(IRI ZS (o~un L I' u, -212,0-11' CIGI(TS I _L I I ~LB szs --1)-=-237 -----t)--- F*ICL AIILHOCIL) -241 '233 -109 VACUUM GWITC~I -221 ·o"--~e ._I zs VOLTAGE IoA Y REGULATOR 99 LAMP CAMP .r 12 SYJI rULLSLICCIOH COIIYIU 814 1211 -232-----1 -273-8 ~ulo ruo~ ;j' -230 23 7 -230~ L ao* 34 49 CIGAR LIG~ITER LP 1 INSTIIUMENT PANEL POS1 -233 .211 LIWITS PROOEY (IS~ FUSESZ ICVL)IEIO rlllP. ?60--1111 CLC'iTER -Ilo GVAOEt -169 MASTERI~I I II i, SWITCH m~ m -lJJlll OIL~IHP U- -210 -121 ~u -200 -212 Ll\NOING 1 L -21" -119--·~37 -2~2 LIGHT MAGNETO --123 slclll -lee Iv swlrcll IOWlrl(lH (Slld~ LIGHT ASSEMBLY WIHC~ CREEH MAONETO -142--111 19L qa LECT "@"P"a B 7- -a-·· Iz?r -270 PL to .Ir -64 ----t)-- -91 us *L 82 -209 nas- -eea ~v ~55 STARTER ~d-- "3--- -~72 --274 12il ~264··_ VIBRATOR IQ ROT*TWG OE*COHOPI 141 8~- -126 ss_ b. LIGI1T ASSEMBLY iT HIHG,RED 42 t: res PITOT lOe w STAI\TER WWER 4 ms SOI.ENOID RELAY FnlllPLIFFITIsland EnterprisesI IS'1I FICORE 13-15 ELEC'TRICAL SYSTE~ DIAGIIIAM (196~ M20E S/~J 514, U32 Ilrru 13UU) cmcul-r ""5"""" -153 9 'I~-- -199--- -190--- 107 ----1------~WITCII GEAR WAIINING pnr·,uLI HIHIII)(E MB SWITCH ZZ -24o INDICAOR (LIFI UEIEL(OR) ,Irr WIRLI~ 1665 NOTEENOTE -14 RADIO -2l0--Lf)--216 1 BMIM2-II BUI sIR (NF) (1(1 )IOTC 3( RADIO T RADIO SPEAKER 99 OPT RADIO L---- GENERATORII --1 ·las ==I[APP~1 -143----1>-- -170--111 SWITC)( ZS 2A DO)(L LIG(II( I ~VIICH ~LIIHOLI GCAA VIRlllltO. INDICATOR Junle (olvn I· i. IIIROT~LEma3 v~s )-(ORN LIGHTS crAn w~slallo 929 --3>--~-2151 ----1)---234 -231------lyr PlbLL *~ILHOLIEL O ifR r- -241 "259 (*PP LIG)IT LIGI(T I~L SWITCI1 GEAA ~IRWI1(0 ~r*n u*nlello 29 VOLTAGE Bq -;M5·b~ -112-1v REGULATOR .r ~22. aLAMP ii.·FUEL 1ELLC~OR -262 S)IUNT 236 mro ,Ilo~ -237 -250 z ------~r, -134 ·2~0 ------·71 ~Z to* 48 glu~- I I CIGAR L.IGIITER 251 6P C_I 1 I t- I -eo6 PANEL I'O~' re -211------LIGIITS PROBE FUSE YZ CIL· IIL*D ~O(P. ·-260--(11 -100 '1 CLUSTER -110 ~la ouAo E -169 MASTEA SWITCI( U1 ·---CONNE liZ -133111 37 OIL Ir~P ha 3L -210 -121 -200 LIGHT MAGNETO -125 AICHT -203 t 262 IH SWIICH -150 laalrlole (illRr --151 LIG)1T ASSEMBLY 'I HINb) bAEEH MAONETO ·Rlb(tl -152 -260 IQL rtrr a B T -d·uvr~ZL .u -270 I 81 -266 Io Il -\jq 91 TAIL LIGHT ASSE)c.OLY 129 ------1)--- -i -215 12L BZ 5* ~-269 -61.--~-- 62-,)-- --~r ·265 -273~)-- -lii2~--274 STARTER 11~---- -es 0""'" Io* VIBRATOR .4 1140~ A ROWIHG OE*CON·OP~ -I·,J --194 9s_ fi. LIGHT ASSEMBLY lo* 42 HIIG,RED LPI PITOT STARTER WWER 4 OPIOH*L FUEL PUHPELEe'lkle SOLENOID RELAY ~na NOTE: AI.L ITEM NUMBERS ARE UNDERLINED (REFER TO ELECTRICAL EQUIPMENT LIST). Island Enterprises FIGURE 8-16 ELECTRICAL SYSTEM DIAGRAM (1967 M20C&E SiN 670001 8( ON) m M2OE ONLY 203 105 ii; m ,t.. an b GEAR WI\IININ~ 120 PIIESTI\LL WARNING sWlrC,1 z POWER BOOST PoWCR BOOST 9 (LIFT DETECTOA) -217 0 WnRNINO LIGIIT WnnNINO SWITCI1 n an -175 -104 ·2(13 7 nnolo 216 m M2OC ONLY 0 OPT L 1-11------171- 9g o JL~PLe-_nAPlo -----111 G-I rucmlo it] PROBE 1 99 RADIO SPEAKER TEMP SE)/SINO CY~UVnE70n PLUG i .Jj 3 t-----·111 r3 DOME LICI(T D SWITCII nSSEMDLY -as GEAR WIUININC OENTIIATOI1 T TURN COORDINATOn -zso-ff,-o--EJII TIIROTTLE F -54 -112 I I I LIGHTS LIGHT 19 PANEL A98EMOLIC9 INDICATOR 2 O WnRNINO 11 51\ a -259 cnna nlR TEMP. LIGHT -233 IP 14 CEnn WAnNINo an R)IEOSMT SWITCH -29~ 95 L~ -221 -241 ·235 -Os;n~-lll -30--~---51 -250 va~mer lo* 1 -~c`00--)I (10 ul AtcuL~ron F LI\M[' 30 14 3 ~itl Z r 4811114$)---243 FueLsELEcron -2az SI(UNt -230 SHUNT LIG)ITS 13~ nllEosTnT 120 000011-1 F ou~ n~n FUSE Ill 07 CIGAR LICIITER 69 05 9.,,, PROBE FUSE 92 CYL.)IEAD TEMP. 209 -260 --111~1 CLUSTER ~J: 4 GUAGE 66 -169 MASTER SWITCH (I! CONNECTOR COMPASS 6ULB OIL TEMP. a LANDING 213 HaoaEm I RIGHT -203 ,L~nr 102 -69 -71 Iw SWITCH LIGHT ASSEMBLY IGNITION 8 START WING,OREEN INBOI\RD INBOnRD 151 (COHNECT Y1IIlOIWO IH .277 FUEL aUIHTITI FUEL OUIHTITY Rer RECLPTIUI. INO 0110) TAIHSLllrTERS TR~NS)IITTERI -142 ----111 93 LEFT RIO(1T 43 MALGENF~TO 1 :B ~I I F F ~_ -$2 -215 121 .00012-13 BVS B~R ~193 STARTER 122 8- 11~-----261 LIGHT 56 VIBRATOR IOA -204 IS LIGHT ASSEMBLY 50LIGM TP~IL, WHITE ASSEMBLY 49 -3)--93-))---94 55 WING,REO 42 SLOPE MARKER BEACON PITOT HEAT 00 109 STARTER POWER ELECTRIC SOLENOID RELAY iiji733~.'84 FUEL PUMP NOTE: ALL ITEM NUMBERS ARE UNDERLINED (REFER TO ELECTRICAL EQUIPMENT LIST). Island Enterprises SHOP NOTES S-2d Island Enterprises ELECTRICAL EQUIPMENT LIST (M20C, D a E) NOTE: Item numbers refer to underlined numbers on ELECTRICAL SYSTEM DIAGRAMS NO. ITEM QTY. RATING M~IUFACTURER MODEL/PARTNO. I Generator 1 50A Delco Remy 1101915 2 Voltage Regulator 1 50A Delco Remy 1119224C 3 Circuit Breaker-Generator 1 50A Wood 2350 4 Battery 1 35A Auto-Lite R-35 5 Switch-Generator 1 55A AN3022-2 6 Switch-Master 1 55A AN3023-2 7 Starter 1 Delco Remy 1109689 8 Switch-ignition andStarter 1 Bendix 10-126690-1 9 Circuit Breaker-Gear Warning 1 5A Klixon PSM-5N 10 Light-GearWaming (Green) 1 .08A Dialco VM9118M-3A 11 Switch-Gear Warning (Retr. Handle) 1 3A Micro BZ-7-RWT80 12 Switch-Gear Warning (Throttle) 1 25A Micro BZ-7-RQIT 13 Horn-Gear Warning 1 .7A Edwards 319 14 Light-GeatWaming (Red) 1 .08A Dialco VM911-M-2A 15 CircaitBreaker-Fuel Pump 1 5A Klixon PSM-SN 16 Switch-FuelPump 1 40A Micro AN3021-2 (511TS1-2) 17 Pump-FuelEIectric 1 1.5A Bendix 476087 18 CircuitBreaker-Fuel Gauge 1 5A Klixon PSM-SN 19 Gauge-FuelQuantity 1 AC 5643860 20 Switch-FuelGauge 1 40A Micro AN3021-3 (511TS1-3) 21 Gauge Unit-Fuel Tank, Right 1 AC 5641991 22 Circuit Breaker-Stall Warning 1 5A Klixon PSZllI-5N 23 Indicator-Safe Flight (Stall Warning) 1 Safe Flight 164-R 24 Pre-StallWarning Switch- Lift Detector 1 Safe Flight C-46001 25 CircuitBrealrer-Turn and Bank 1 2A Klixon PSM-ZN 26 Indicator-Turn andBank 1 4.2W Schwein NS27200-A1 27 CircuitBreaker-Nav, Lights 1 10A Klixon PSM-1ON 28 Switch-Navigation Lights I 40A Micro AN3021-2 (511TS1-2) 29 Lights Assembly-Wing 2 1.6A Grimes A1285 30 Light Assembly-Tail 1 1.15A Grimes A2064-12 31 CircuitBreaker-Landing Light 1 35A Klixon PSM-35N 32 Switch-Landing Light 1 55A AN3021-2 33 Light-Landing 1 100W #4537 34 CircuitBreaker-Paner Lights 1 5A Klixon PSM-5N 35 Rheostat(25r)-Panel Lights 1 Clarostat #25-25 36 Light-Panel Assemblies 2 .63A Grimes A1425-R 37 LampCompass 1 .08A 330 38 Lamp-FuelSelector 1 .08A Dialco 83B1310-117 39 CircuitBreaker-Dome Lights I IOA Klixon PSM-ION 40 Lights and Switch Assembly Dome 1 1.15A Grimes B3j55-A-93 41 Ammeter 1 0.60A AC 1502373 42 Solenoid-Starter 1 Delco Remy 001464 43 Magneto-Left 1 Bendix S4LN200 44 Magneto-Right 1 Bendix S4LN7,04 8-27 REVISED NOVEMBER'1966 Island Enterprises NO. ITEM QTY. RATING MANUFACTURER MODEL/PARTNO. 45 Vibrator-Starting 1 3A Bendix 10-87998-1 46 Switch-Starter Solenoid Cutout 1 40A Micro AN3021-2 (511TS1-2) 47 Voltmeter-Turn and Bank I Weston Elec. 840 (or Equiv.) Inst. Corp. 48 CigarLighter 1 8A Balcamp n"4-2272 49 Heated PitotCircuitBreaker 1 10A Klixon 0-7270-5-10 50 Rotating Beacon Circuit Breaker I 10A Klixon D-7270-5-10 51 ADF Radio Circuit Breaker (For ADF-29) 1 2A Klixon PSM-ZN 52 ADF Radio CircuitBreaker (For ADF T-12) 1 5A Klixon PSM-SN 53 Fnse andFuseRetainer 1 IOA Little Fuse lo AMP 311014 and 155020A 54 LoudSpeaker 1 Oxford 46 AMS 55 Pitot-Optional 1 8A Aero Instrument P.H. 502-12 56 Rotating Beacon-Optional 1 6.62A Grimes G-8400-8-12 or 0-7080-1-12 57 Radio-Optional 58 ADF Radio-Optional 59 Receptical-Extemal Power 1 AN2552-3A 60 Solenoid 1 Delco Remy 001464 61 Connector-Electric Plug 1 AN3106-14S-1S 62 Indicator-Carbu~etorAir Temp. 1 1.5 AMP Richter C-12 63 Probe-Temperature Sensing I Richter B-5 64 Adaptor-Electrical Accessory to Cable 1 AN3057-6 65 PowerRelay 1 100A Cntler-Hammer 6041H34B 66 Bulb-OilTemperature I. AN5525-1 67 Plug-Connector 1 AN3106A-125-3S 68 Clamp-Cable 1 AN3057-4 69 Probe-CylinderHead Temp. 1 AN5546-1 70 Adaptor 1 AN4076-1 71 Switch-Master 1 AN3027-2 72 Shunt 1 60A Weston Elect. 105918 73 Speaker-Radio 2 Jensen P4-W 74 Light-Landing 1 250W G.E. or Equiv. 4522 75 Circuit Breaker-Radio 2 10A Klixon PSM-1ON 76 Circuit Breaker-Radio 1 2A Klixon PSM-2N (Por ADF-T29) 77 Circuit Breaker-Radio 1 5A Klixon PSM-SN (For ADF-TL2) 78 Circuit Breaker-Instrument and Domt: Light 1 5A Klixon PS(M-SN 79 Circuit Breaker-Instrument 1 5A Klixon PSM-SN 80 Circuit Breaker-Ignition 1 10A Klixon PSM-ION 81 Circuit Breaker-LandingLight I 20A KIixon D7270-5-20 82 Circuit Breaker-Navigation Light 1 5A Klixon 07270-5-5 83 Circuit Breaker-Rotating Beacon 1 10A Klixon 07270-5-10 8-28 Island Enterprises NO. ITEM Qm. RATING MANUFACTURER MODEL/PART i~iO. 84 CircuitBreaker-Fuel Pump 1 SA Klixon D7270-5-5 85 Indicator Lights-High and Low Vacuum I .08A Garvin 23-602 86 ClusterGage 1 0.1A Garwin 22-166-01 87 CircuitBreaker-Buss Bar 1 50A Wood 2350 88 Switch-Landing Gear Warning-Throttle 1 10A Micro V3-1 (AN3234-1) 89 Indicator-Turn andBank 1 .3A Garwin 23-323-01 90 Switch-Press to Test High and Low Vacuum 1 SwitchCraft 974-TF 91 Fuse andFuseRetainer 1 10A Littlefuse 10 AMP 311010 and 155020 92 Fuse andFuseRetainer 1 10A Littlefuse 10 AiMP 311010 and 155020 93 Fuel Quantity Transmitte~- Left I AC 5642354 94 Connector-Electric Plug 1 MS 3108B 10 SL-3S 95 Vacuum Switch (High and Low Vacuum) 1 Garwin 22-1280-04 96 Indicator-Carburetor Air Temp. 1 Garwin 22-995-04 97 Connector-Electric Plug I AIu'3106B-14S-7,S 98 Circuit Breaker 1 (See Notes 31 and 32) 99 Circuit Breaker As (See Note 32) needed 100 LightAssembly-~Ving, Red 1 1.6A Grimes A1285-EI-12 101 LightAssembly-Wing, Green 1 1.6A Grimes A128j-G-12 102 Switch-Ignition and Starter 1 Bendix 10-126680-2 103 Speaker-Radio 1 Dare 721120 (V5F43) 10~ ClusterGauge 1 0.1A Garwin 22-166-04-A 105 SwitchAlt. Air\arming (Ait. Air Control) 1 25A Micro V3-1 (AN3731-1) 106 Indicator Lamp 1 .08A Dialco 39-14-371 7538-XP13 7538-XP51 107 Electric FuelPump 1 5A Dukes Ast. Co. 4140-00-19 108 CircuitBreaker-Fuel Pump 1 10A Klixon D7270-5-10 109 Electric Fuel Pump I 5A Dukes Ast. Co. 4140-00-21 110 Cluster Gauge 1 0.1A Garwin 22-166-05-A 111 Connector-Cluster Gauge 1 AN3106B-18-85 AN3057-10 11' ClusterGauge 1 O.IA Garwin 27,-166-010 113 ClusterGauge 1 0.1A Garvin 22-166-09 11~ Speaker 1 Tramm SP-1 115 Rheostat Panel Lihts 1 3,.O~A Ohmite 919006-1 116 Lights-Panel Asseirlblies 2 .63A Grimes A-1435A-1-12 117 Li_ehtBr SwitchAss?-Dome 1 .58A Grimes B-3555A-89 118 ClusterGage 1 0.1A Garwin 660100 27-169-07 119 ClustrrGa_ge 1 0.1A Garwin 660099 22-169-08 170 Rheostat Post Lights 1 1.19.~ Ohmi tz 919006-501 1'1 StarterVibrator 1 2.75A Gar\t·in 31-324 122 Light Assv-Tail 1 l.f2A Grimes A-3064-1'777 173 Power Relav 1 100.4 Cutler-Hammer 604111231 124 TerminalStrip 1 Kulka 599-7_003-6 125 Turn Coordinator 1 Brittain Ind. TC100-12 1'6 Turn Coordinator 1 Brittain Ind. 2900TC100-11, 137 Shunt 1 Garwin 7,2-370-60 138 Horn-DualWarning 1 Safe-Flight 283 139 Switch-Ignition gi Starter 1 Bendix 10-357201-1 REVISE~ NOVEMBER 1966 5-29 Island Enterprises I. All splices are A~IP knife or equi~alerlr. 2. I\llcircuitbrlskers areof dtrlp-freetype 3, r\ll terminals are A5~59 (or equivaient\, or wire e~id· ar~ 4uldc-c~1 4. All unshielded cable is to conform to.rpzc (~i·I ~otr 5. All terminals will be of a prein;nlated type or will :,e inplllar~d tllhl~Lm q325134 may be used on ~ci tennin~lJ; amp·uiatior? r3W11- Illav be ~,cd r·rr ~=et-nlir:Jlr i;. Deleted teads without dash nlllTlbrTS are iu·rn~hej with ths co;.celilcd. 8. Plastic resin-core rolder is used. 9. Deleted 10, "F" symbol indicates groundilig through iralnz Ino wires,, r- Yymbol jigmii~ a kllifedirc·oFliec~ 12, Connect optional equipment wires to oower ~o.lrce ~IIIY ~ilZ:lot?ti3lidl is tll~tallid II; sulate terminals rzirh Sco~ch t53 tape wi~err terlniujls 3rz r.L·~ canr:~c·iP-d 13, Install items 49 or 90 jcircuit breakers') only whal hcrt:ed pl:n; or rotiltillg br?df~ll Ir inji;t[li(j 14,. 15,. 16,. 17.. 18, Deleted 19, Wires, knife disconnects. gage, probe. and gage coane~tors a·~ In tiicczi Probe Kit, 21,, 22,. 23, Deleted 24, All,j18 ~ielded electrical cable is to conform to ·pecification S1!1,-<:-~O'x I ype 25., 2(i,. 2;. DEler~d 2x. Ppare parts replacement for -58 wire should also irtclude -15: ~ire· 15 I;i)l-i~SI s 29. IDare parts replacement for -IS wire should al.;o incl~lde -1;-i wire. 1;01-1431 y 1Y53-I~:(9i. 30, An external power supply plug installation is available as cp·ior;al eqliplrlenc. 31, This circuit breaker is for one Sav:Coln uilit only. Do not add other eailp~nc·nr to this clrcua 32, Deleted 33, Install ANP 32446 knife disconnect to shielding on each end of -189 or -218 wire froln 1.00" to 1.SO'' from terminal ends of inner wire, 34. Shielding from wires -19. -20. and -21 is connected together in receptical ASii59-5 and connected to ground terminal of item 8 (ma~eto switch), 35. from Shielding wires -150. -151. and -152 it connected together in receptical AS(i59-5 and is con- nected to ground terminal of item 8 or item 102 (ma~eto switchesl. 36, Xutolite R-35 battery is interchangeable with R-33 and may be used as spare parts replacement on prior M20B and hiZOC models, 37, The high and low vacuum warning lights. with their wiring and twitches. are optional equipment on the h·f20D. and are to be installed only in conjunction with the vacuum system installation, 38, Install X~IP 32121, ampsulation (0.5" lon~ and A~IP 327216 ampsulation on soldered colnections at gear warning lights, and cover with AXfP 32;219 ampsularion(O.r5" lon~-effecdvz ~1'20C S 2657 Sr 0?5); h·i20E 131 5: t3S). Also iiLc:all.L\.\IP 327217 ampsnlation i0.5" arld 327216 ampsulation on oldered connections at the vacuum rr;trIlirlg ~ILOC i,; S 3155 and ErI20E (S~S 833, Sr OSi. 39 The compass light shall be connected tothepo-~;-lidnr. when optional post I~htd are installed, I~he -230 wire, when not attached to thepost lights. will be insulated at the knife disconnect with A~II-' 32'7217 ampsulation and also string tied with Airter !CZass 2, string, 40. The following pairs of wires will be twisted together counter-clockwise with a minimum of three i3) wraps per foot, (Effective M70C S~ 3287 OS, hi?OD,C;S 260 ~L OS~ hi20E S~ 951 Sr OS\: Wires -267 Sr -91 Wires -2Ci-!&-5 -7ci2 Sr -92 -263 -90 -268 Sr -6·1 -269 -39 -2:0 Sr -tjO -274 Sr -94 -266 Sr -81 -272 -93 -1?65 Sr -82 -273 Sr -1:1 -261~ -1·10 41, Use 919012 overhead light as replacement part on M20B E 'S 1701-1851: 1853-1939. h121X: ~35L 1940 Sr O~: hi20D S,'S 1. 101 Sr )h'; Xf20E 5 i~ 101& OS. Use 919012-501 overhead Zi~ht on ~1200 S/N 1701-1851, 1853-1939; ~IZOC S/h' 1852. 1940-3184: XIPOD S/~ 1. 101-2591 ~170E 8 ·S IOI-YRI. Use 919012 overhead light on M20C S~ 3185 Sr OS. 113-OD S 260 Sr O~. alld S120E 5 IS 832 c)S. 8-30 REVISED NOVEMBER 1966 Island Enterprises Item So. 125 may be used to replace Item No. 89 without changing wires or connector. (Effective ~120C S:S 3135 g: O~i; ?cI20D S;S 260 a; OZc~; ~20E S~i 832 a; oN. ·13. The polarity of wires 800007-180 and -181 is not eritical. ;1. On Zvi20C, 1~ 670001 OS. and Af20E. 670001 ON', wire 800007-143 connects to positive lead from Brittain turn coordinator ltem No. 126. 45. Garwin shunt parr no. 22-370-60 replaces shunt pan no. 105913, effective M20C. S~J 670001 8i 05, and hI20E, S~ 610001 ON. REVISED NOVEMBER r966 8-31 Island Enterprises FIGURE 8-17 ELECTRICAL SYSTEM DIAGRAM (1967 M20F S/N 660003 6'/0001 ON) T 2 111---122 SWITCI1 4-0vp! GEAR WARNING PRESTIILL WARNING SWITCII POWER ROOST POWER ROOST 54 ILIFT DETECTOR) WARNING LIO)(T wARNINO 9WITCll II ~T?? ·123 -079 ~Mple, 1022 ..nAPlo 60 -o(B d,,,, _. --111 a. t L~ 1 ·I dbP~e, RADIO SPEAKER GENERATOR -124 SWITEII _ GEAR WI\RNINO T a DONE LIGI(T D ASSEMOLY 24 TURN COORDINATOR -117 T V 35 TIIROTTLE ------~--·-054 "LIGHTS LIOIIT ~U PANEL ASSEMOLIES -12C,D an o WnnNII~O ·lor I 1 2 LI611T -oso 3 re cEnn WAnNINC I(~IEOSTAT SWITC)I F 19. (14 -043 -043 .055"9 -~-aol-tt III ·01(4 VOLTI\~E IOA ·i4--·ll~ REGULATOR af HI r LI\MI' 1~ FUEL SELECTOR S)(UNt SIIUNT LIGL(TS 2 IIIIEOSTAT 1 r 42 ZP D ZR eP ~.osi --OUIOln10 osolll·o Ce4 wlnr(nrr~2 26 FUSE SL CIGAR LIOIITER ·062 1l -020 PF(OOE ~-063 1? -1 I FUSE 29 -040 CYL.)ICdU rEMI1 -132 -041 ---111 -192 CLUSTER ·011 I 10 ounoc: SWITCII 4,BCONNECTOR COMPASS ullll,~ a LIOI1T OILTEMP I I I I 1-131 g7 LIG~(T MAONETO 1~ I ILnNolNo AI[I~IT -100 -036 -038 I IW SWITC~I LIGHT ASSEMDLY IGNITION B START WINO,OREEN IN0OnnD INOO~R3 (CONHFCr IIIIELDIH~ IH RLELPTIWL*HDWIO) .IJ6 31 TULL OUll(flr·l MAONETO IR*hlSUlll~ltS ;0 Lrrr 4_3 LEFT --II' AIGI(I m 33 -140 67 A .a 11---088 -087 ~-:o7jfF-lll V B 92 OUTBOIUIO 9' 1 -084 C~ La 5n llt----096 -095 --~-cirJ4 -009 F 2 75 ~--09- ,--;139 STARTER OUS OAR ANTI-COLLISION O 11' -050 LIGIII 32 VIDRATOR n -003 m LIGHT I\SSEMBLY 3 111----111---1)_-110 TAIL, IV)IITE LICI1T ASSEI~BLY m 65 WINO,RED a ·0-·-lc~·xIx g ·-CLIOL ELOPE MARKER DEACON 90 42 .B ~4 PITOT )1EAT ·o STARTER POWER 69 ELECTRIC o~ SOLENOID I(ELI\Y 9 3~-113 OI 1OA FUELPUMP NOTE: ALL ITEM NUMBERS ARE UNDERLINED (REFER TO ELECTRICAL EQUIPMENT LIST~. Island Enterprises ELECTRICAL EQUIPMENT LIST (M20F) KOTE. Item numbers refer to underlined numbers on ~120F ELECTRICAL SYSTEM DIAGRAMS ITEhl QTY. RATING iLIANUFACTURER MODEL/PART NO. 1 Generator 1 12V Deico Remy 1101915 50A 2 Regulator-Voltage 1 Delco Remy 1119724C 3 Vibrator-Starter 1 2.75A Garwin 31-324 12V 4 Battery- 1 35AHR Rebat R-35 5 RelaJ'-Powlr 1 12V Cutler-Hammer 6041H231 0.67A 6 Gage-Cluster 1 0.1A Garwin 23-169-07-1 hrlooney P/N 660114 7 Starter 1 12V Prestolite M24206 8 Probe-OilTemp. 1 AN5525-1 9 PlilS-OilTemp.Probe 1 MS3106A-125-35 10 (GzarDown) 1 12V D.ialco VM911~1-3A 0.08A 11 Switch-Gear Warning Handle 1 Mirco BZ-7R\YTBO 13 Clamp-Cable(Oil Temp. Plug) 1 MS-3057-4B 13 Plobr-Cly. Bad Temp. 1 AN-5546-1 1~ Light-Warning (Gzarup) 1 1'V Dialco VM911M-2A 0.08A 15 Light-Warning (HighVacuum) 1 12V I)ialco VM911M-2A 0,08A 16 Light-Warning (LowVacuum) 1 12V Dialco VM911M-2A 0.08A 17 Adapter-CylinderHzad Temp. 1 AN4076-1 Probe 1S Switch-~laster 1 Mirco 512TS1-2 MS35059-22 19 Shunt 1 Garwin 22-370-60 20 Trans.-Fuei Qty. (L TanL Inbd.)l A-C 21 Trans.-Fuel Oty.(RTankInbd.)l A-C 22 Switch-Gear Warning V3-1 Throttle switch with actuator 1 Mirco JV-5 23 Turn Coordinator 1 12V Brittain 820166 0.75A 2~ Suritch-Warnin_p pre stall I Safe Flight C-46001 Mooney P/N 800218 35 Fuse gr Fuse Retainer 1 Littlefuse 311010 155020 26 Fuse&Fuse Retainer 1 Littlefuse 311010 155020 37 Light-Landing 1 250\Y GE or Equiv. 4522 12V 25 Relay-Over Voltage 1 RBM 136-8 Mooney P/N 800165 19 Vacuum) 1 Garwin 22-1280-04 30 Light-Position !Red) 1 1.6A Grime s A1285-R-12 12\' Mooney P~I 800223-Basic 31 Light-Position (Green) 1 1.6A Grimes A1385-G-12 l'-V Mooney P/N 800223-501 REVISED NOVEMBER 1966 8-33 Island Enterprises NO. ITEM OTY· RATING SIANUFACTURER MODEL/PART NO 32 Light-Position-tail 1 1.6A Grimes A1064-1777 12V Mooney P/N .500274 33 Switch-Ignition andStarter 1 Bendis 10-357210-1 34 Switch-Warning 1 Mirco 53-1 (Alt. Air Control) JV-5 35 Light-Panel(left) 1 0.63A Grimes A1425A-1-12 12V ~ooney P/N 919012-Basic 36 Light-Panel(Right) 1 0.63A Grimes A1125A-1-2 12V ~looney P/N 919012-Basic 37 Compass 1 0.08A Airpath C-2350-DL-4VF 38 Light-FuelSelector 1 0.08A Dialco 203-1310-01117-201 12V 39 Speaker 1 Tramm SP-1 40 Light--Warning 1 0.08A Dialco 39-14-373 (Alt. Air Control) 12V 41 Pump-Electric Fuel 1 5.GA Dukes 4140-00-19A 12V 42 Solenoid-Starter 1 3~0A Delco Remy 001466 12V 43 Magneto-Left 1 Bendix S4LN200 44 Magneto-Right 1 Bendix S4LN204 45 Plug-Cluster Gage 1 SIS3106A-18-85 46 Rheostat-Panel Lights 1 Ohmite H-8-F2-352A Mooney P/N 919006-1 47 Rheostat-Post Lights 1 Ohmite H-8-F2-352A Mooney PIN 919006-501 48 Lighter--Ciger 1 8.GA Balcamp 4-2272 12V 49 Light-Dome 1 ~58A Grimes B-3555A-89 12V 50 Circuit Breaker-Generator 1 50A Wood 109-250-101 51 CircuitBreaker-Buss Bar 1 50A Wood 109-250-101 52 CircuitBreaker-Pre Stall 1 5A Klixon PSIM-SN Warning Mooney P/N 919000-9 53 CiIcuitBreaker-Inst, &Dome 1 5A Klixon PS~M-SN Lights ~viooney PfN 919000-9 54 Circuit Breaker-Cluster Gage 1 5A Klixon PS1M-M Vacuum Warning Mooney P/N 919000-9 55 Circuit Breaker-GearWarning 1 5A Klixon PSM-jN Mooney PIN 919000-9 56 CircuitBreaker-Torn Coord. 1 2A Klixon PS~M-2N hiooney PIN 919000-5 57 Circuit Breaker-Ignition I 10A Klixon PSXS1ON Cigarette Lighter Mooney P~N 919000-13 58 Circuit Breaker-Audio Cent. 1 2A Klixon PShl-2N h.looney P/N 919000-5 59 Circuit Breaker-Radio 1 Klixon h~ooney P/N 60 Circuit Breaker-Radio 1 Klixon Mooney P/N 61 Circuit Breaker-Radio 1 Klixon Mooney P/IN 8-34 REVISED NOVEMBER 1966 Island Enterprises NO. ITE~1 QTY. RATING MANUFACTURER MODEL/PART NO. 62 Circuit Brcaker-GzarCont. 1 5A Klixon PSM-SN Mooney P/N 919000-9 63 CircuitBrealrlr Switch 1 Klixon D-7270-5 Glide Slope 64 CircuitBrlalcer Switch 1 Klixon D-7270-5 Mark Beacon 65 CircuitBreaker Switch 1 10A Klixon D-7270-5-10 Heat Pitot 66 CircuitBrcalrer Switch 1 10A Klixon D-7270-5-10 A-C Light 67 CircuitBreaker Switch 1 20A Klixon D-727d-5-20 Landing Light 68 Circuit Breaker Switch 1 5A Kiixon ~ji70-5-5 Position Lights 69 CircuitBreaker Switch 1 10A Klixon D-7270-5-10 Fuel Pump 70 Horn-DualWanring 1 014A Safe Flight 283 0.3A Mooney P/N 800185 71 Pitot-Heated 1 8.GA Aero-Inst. R.H. 502-12 12V AN 5812 72 Light-AntiCollision 1 6.62A Grimes D-7080-1-12 12V 73 Reiay-ExternalFbwer 1 0.69 Cole-Hersee 24059- 74 Buss Bar-~lain 1 Mooney P/N 800012-1·1 75 Buss Bar-Ausiliary I Mooney P/N 800012-13 76 Buss Bar-Power 1 Mooney P/N 800012-7 77 Buss Bar-Radio 1 Mooney P./N 800012-7 78 Terminal Strip--ShuntLights 1 Joy Ailfg. Co. 520077-251 Mooney P/N 919008 79 Light ~aming-Generator 1 0.08A Sloan 1065-R-F32 Mooney P/N 913067-Basic 80 Clamp-Cable(Cluster Gage) 1 MS3057-10B 81 Connector-Ait. Air 1 Dialco 7538-XP12 82 Speed Clip-Alt. Air light 1 Dialco 7538-XP51 83 CircuitBreaker--Gear Actuator 1 25A Klixon D7271-8-25 84 Switch-Up Limit (w./actuator) 1 Mirco DT-2R-A7 Mirco iMCD2711 85 Switch-Down Limit 1 Mirco DT-2R-A7 (u~/actuatoI) Mirco MCD2711 86 Srdtch-Gear Safety 1 Dukes 3203-00 Mooney P/N 950161 87 Switch-Gear Control 1 Mirco 1TL149-30 88 RelaS·-GearUp 1 ~50A Cutler-Hammer 6041H50A 12V 89 Rtla~-Gzar Down 1 0.50A Cutler-Hammer 6041H50A 12V 90 Actuator-Landing Gear 12V Dukes 4196-00-1B- Mooney P./N 950158-501 91 Receptical-E~.uterna1 Ebwer AN2552-3A 93 Trans.-FuelOty.(L. Otbd.) A-C 93 Trans.--FueiOty.(R. Otbd.) A-C REVISED NOVEMBER 1966 S-35 Island Enterprises NOTES .1120F (ELECTRICAL SYSTEM DMGR~SI) i. All splices are AMP knife disconnects or equivalent. 2. Allcircuitbreakers areofatrip-freetype, 3. All terminals are AN659 (or equivalent), or wire ends are soldered together: 4. All terminals will be of a preinsulared type or will be insulated with ampsulation or equivalent ma- terial. 5. Wires without dash numbers are furnished with the ecluipment item. 6. "F" indicates grounding through frame (no wires). 7. symbolindicates a knifedisconnect. 8., All mil-spec. wires may have any revision letter. Example: Mil-W-50S6 may be MiI-W-5086A 9. The symbol signifies optional erpipmenr that maybe installed as desired. 10. The following` pairs of wires must be twisted together counter-clockwise with a minimum of three wraps per fodt: Wires -085 -088 Wires -139 Sr -138 -084 -087 -097 Sr -105 -083 Sr -088 -098 Sr -099 -089 Sr -096 -050 Sr -114 -090 Sr -095 -106 -111 -091& -094 -107& -110 -092 Sr -093 -108 Sr -109 8-36 REVISED NOVEMBER 19ib Island Enterprises SECTION IN STRU NIENTS Island Enterprises SECTION IX INSTRUMENTS A. GENERAL The instrument panel has been designed to provide functional location of all flight, radio, and engine instrument groups. All flight instruments are grouped on a shock-mounted panel directly in front of the pilot. They are located in such a manner as to provide maximum efficiency for instrument cross-check, a most im- portant item for IFR flying. A radio panel is located in the center of the instrument panel and has sufficient room for tworadios. The glove compartment slot serves as a mounting area for a third radio. All of the engine instruments are grouped on the co-pilot's panel. B. TROUBtE SHOOTIE~G When trcuble shooting instruments having an electrical power source, check from the power supply to the instrument affected. If no malfunction is found, the trouble probably exists inside the individual instrument. The instrument then should be replaced by an identical instrument, tested and known to .be operating properly. See Table 7 for instrument trouble shooting procedures. SHOP NOTES 9-1 Island Enterprises TABLE 7 INSTRUMENT TROUBLE SHOOT1NG TROUBLE CAUSE RES1EDY COhlPASS Excessive card error Compass not properly Compensate instrument. compensated Refer to Service Instruction M20-23. External magnetic Locate magnetic interference and I interference or aircraft eliminate if possible. Demagnetize structure magnetized. structure. Excessive card Improper mounting an Align instrument. oscillation instrument panel 1 Insufficient liquid. Replace instrument. Card Sluggisk Weak card magnets. Replace instrument. Excessive friction or instrument. II pivot i Replace broken jewel. H Instrument too heavily Remove excess compensation. compensated. and compensate instrument. Liquid leakage. Loose bezel screws. Replace instrument. Broken cover glass. Replace instrument. Defective sealing gaskets. Replace instrument. Discolored luminous mark- Age. Replace instrument, Ings or damping liquid. Defective light. Burnt out lamp or bmken Check lamp or continuity of wiring. circuit. No on indicator reading Broken Shaft. Replace shaft (either permanent or inter- mittent). Springs weak Replace instrument. Pointer oscillates I Rough spot or sharp Repair or replace. excessively. bend in shaft. Excessive friction in Replace instrument. 11 instrument. 9-2 REVISED NOVEMBER 1966 Island Enterprises TABLE 7 (Continued) TROUBLE CAUSE REMEDY ALTIMETER Escessive scale error. Improper calibration Replace instrument. adjustment. Excessive pointer Defective mechanism Replace instrument. oscillation High reading. Improper venting. Eliminate leak in static pressure sys- tem Setting knob is hard to Wrong lubrication or lack Replace instrument. turn. of lubrication. Inner reference marker Out of engagement. Replace instrum~nt. fails to move when setting knob is rotated. Setting knob setscre~ir I Excessive vibration. Tighten instrument screw, if loose. loose or missing. Replace screw, if screw is missing. Cracked or loose cover i Excessive vibration Replace instrument. glass. Dull or discolored lumi- Age. Replace instrument. nous markings. Barometric scale and ref- i Shift in mechanism. Reset pointers and recalibrate. ernence markers are out of synchronism with pointers Barometric scale and ref- Slippage of mating parts. Replace instrument. ernce markers out of sgn- chronisa AIRSPEED INDICATOR Pointer of instrument Leak in instrument case Check for leak and seat does nor indicate or in pitot lines. properly. Pointer of instrument Leak in instrument case Check for leak and seal. oscillates. or in pitot lines.- HEATED PITOT TUBE (IF USED) switch Tube does not heat or clear Circuit breaker Reset. rtself of ice with swich ON. tripped. Replace. Defective breaker. REVISED NOVEMBER 1966 9-3 Island Enterprises TABLE 7-(Continued TROUBLE CAUSE RE~IEDY a Open circuit. Repair. Excessive voltage drop be- Check voltage at pitot head. II tween battery and pitot head. 1 Heating element burned Replace pitot head. out. TURN AND BANK INDICATOR Pointer fails to respond. Foreign matter lodged Replace instrument. in instrument. II No electric circuit. Check for voltage at instrument. Incorrect sensitivity. Misadjustment of sensi- Adjust by means of sensitivity spring tivity spring. screw. If this pulls the pointer from zero, replace instrument. Pointer does not set on Gimbal and rotor assembly Replace instrument. zero, out of balance. II Pointer incorrectly set on Replace instrument. its staff. Sensitivity adjustment Replace instrument. pulls pointer off zero. Vibrating pointer. Gimbal and rotor assembly ReDlace instrument. out of balance. Fitted or worn pivots or Replace instrument. bearings. In low temperature, point- Oil has become too thick t Replace instrument. er fails to respond or does so sluggishly and with in- Insufficient bearing Reoiace instrument. Suificient deflection. clearing. Pointer sluggish in return- Oil or dirt detween damp- Replace instrument. ing to zero and does not ing pistons and cylinders. set when sation- ary. Excessive clearance be- Replace instrument. II tween rotor and rotor pivots. Ball inclinometer does not Instrument out of align- Correct alignment. center. ment on panel. *NOTE: Turn andbank indicatorshavebeen replacedbytum coordinators on all models (l'ttj7 OX). Refer to Section VI for turn coordinator trouble shooting procedures. REVISED NOVEMBER 1966 9-4 Island Enterprises TABLE 7-(Conrinued) RATE OF CLIMB INDICATOR Pointer does not set on Aging of diaphragm. Reset pointer to zero by means of zero. setting knob. Tap instrument while resetting. Disconnsct all instruments connected Pointer fails to respond. Oa-tn~ction in static line. to the static line. Check individual instruments for leaks. Testlines for leaks. Pointer oscillates. Leaks in static line. Disconnect all instruments connected to the static line. Check individual instruments for leaks. Reconnect in- struments to static line and test instal- lation for leaks. It Defective mechanism. Replace instnunent. MANIFOLD PRESSURE Excessive ~mr at e~dsting Pointer shifted Replace instrument. barometric pressure Excessive error when Line leaking. Tighten line connections. engine is running. sluggish or jerky pointer Improper damping Adjust damping screw. movemezlt. adjustment. Broken or,loose cover Vibration or excessive Replace glass and reseat case. glass pressure. Dull or discolored Age. Replace instrument. luminous markings. lines and with Incorrect reading. Moisture or on in line. Disconnect purge air. SHOP NOTES 9-s Island Enterprises TABLE 7 (Continued) TROUBLE PROBABLE CAUSE DIRECTIONAL GYRO INDICATOR Excessive drift in either 1965: instrument air filter Inspect filter. Replace if necessary. direction. dirty @igh vacuum indica- ted). 1966: Vacuum regulating valve filter dirty @igh vac- Test with vibrometer. If amplitude is uum indicated). more than .004 inch, examine shock mountings and note whether connections Excessive vibration ate pulling on instrument. Insufficient vacuum. Correct for insufficient vacuum as fol- If vacuum indication is be- lows: low 3.5 inches Hg· check as follows: i. Vacuum regulating valve i. Adjust vacuum regulating valve. improperly adjusted. 2. of 2. Faulty vacuum gage Check calibration gage. 3. Pump failure 3. Repair or replace pump. 4. Vacuum line kinked, 4· Locate and, if defective, replace or le~aking, or too long for repair vacuum line. Check for col- its diameter lapsed inner wall of flexible hose. I>efective mechanism (worn Replace indicator. or dirty pivots and bearings) I)ial spins continuously in Operating limits have been Cage and reset the instrument with one direction. I exceeded the aircraft level. I>efective mechanism Replace indicator. GYRO-HORIZON INDICATOR TROUBLE PROBABLE CAUSE REiL1EDY 1965: Instrument air filter dirty thigh vacuum indica- Horizon bat fails to re- ted). Examine filter. Clean or replace if spend. 1966: Vacuum regulating necessary. valve filter dirty Ihigh vac- uum indicated). 9-6 Island Enterprises TABLE 7 (Continued) TROUBLE PROBABLE CAUSE REMEDY Horizon bar fails to re- Insufficient vacuum Correct insufficient vacuum as follows: spend. (Continued) resulting from the following: i. Vacuum regulating valve i. Adjust vacuum regulating valve. improperly adjusted 2. Faulty vacuum gage 2. calibration of gage. 3. Pump failure 3. Repair ct replace pump. 4. Vacuum line kinked, A Locate and repair. Check for col- leaking, or too long for lapsed inner wall of flexible hose. its diameter Horizon bar does not set- Defective mechanism Replace indicator. tie. Insufficient vacuum Correct for insufficient vacuum as out- lined above. Excessive vibration Test with vibrometer. If am'plitude is more than.004 inch, examine installa- tion to determine whether flexible hose connections are restricting movement of instrument; examine shock mountings and replace if necessary. 1965: Instrument air filter Correct for excessive vacuum as fol- Horizon bar oscilates or dirty vacuum indica- thigh lows: vibrates excessively, ted). 1966: Vacuum regulating valve filter dirty thigh vac- and clean or uum indicated). Examine filter, replace if necessary. Vacuum regulating valve vacuum regulating valve. improperly adjusted Adjust Faulty vacuum gage Check calibration of gage. Defective mechanism Replace indicator. Excessive vibration i Test with vibrometer. If amplitude is more than.004 inch, exarr·ine~installa- tion to determine whether flexible hose connections are restricting movement of instrument; examine shock mountings and replace if necessary. 9-7 Island Enterprises SHOP NOTES 9-s Island Enterprises SECTION INSPECTION Island Enterprises SECTION X INSPECTION A. GENERAL This section provides instructions for conducting routine periodic inspections. Repair or replace- ment instructions for those components Found to be unserviceable at inspection may be found in the section covering the application aircraft system. WARNZh7G: When working on engines, ground the magneto primary circuit or remove all the spark plug leads before performing any checks on the ignition system. B. PREFLIQFTINSPECTION This inspection is required to determine the generalcondition of the airplane and to detect any damage or maladjustment which might interfere with flight ieliability. The following safety procedure in- structions must become an integral pan of the aircraft owner's operating routine and/or preflight inspection. The airplane should be visually inspected to determine any obvious defects or damage to the foTlowing corn_ponents: Wings Landing gear Fuselage Fuel tanks (Check for evidence of leaks.) Empennage Engine cowling Control surfaces Fuel tank filler caps Check the operation of the following control surfaces for full travel and smooth operation: Ailerons Rudder Empennage trim system Elevators Wingflaps Check the following electrical ecluipment for proper operation: Transmitter and receiver Landing light Position lights Fuel cIuantity gages for both fuel tanks Check the following po~er plant items: Carburetor heat control (Check rv120E power boost door seal for leaks.). En,oine oil for cIuality and quantity. Air filter for cleariliness. Fuel and oil system for any evidence of leakage. Ignition wiring for tightness of connections and conditions of wires. Engine in general for any loose or missing nuts, palnuts, and forproper safetying of allplugs. hla~eros for rpm drop at approximately 1700 rpm or 50 to 65?7, rated power as indicated on manifold pressure gage. The normal drop from both magnetos to one magneto is not to exceed more than 135 rpm. Oil pressure (rninimum idle-25 psi). fuel Pressure (0.5 to 6.0 psi. XI20C D; Is. to 30. psi. M20E). En,oine for proper tune up (650 to 18d0 rpm). Visually inspect the following pans of the propeller: Hub: Allbolts and nuts for ti~tness. Blades: Excessive loss of grease from bearings. If propeller runs rough, check the pitch of the blades (t_0.5" allowable difference) and blade ttack (116 in. allowable difference). 10-1 Island Enterprises C. 25-HOUR This inspection is required to determine the ~eneralcondition of the airplane and to detect any damage or maladjustment which mi~ht interfere with fli~t reliability. The following inspection ~ide is recommended by the factory and should be performed only by qualified personnel. 25-HOUR INSPECTION GUIDE Remove both engine side cowls. Clean engine. Remove and clean air filter. (Check power boost door seal for leaks on all M20E models.) Inspect engine compartment for oil and fuel leaks. Check for security and condition of all ec~ipment in accessory section. Check wing, fuselage, and tail section for dents or damage. Check complete airplane for any damage to control surfaces. Check all instruments for operation, dials for proper markings, and placards for legibility. Check static and pressure system for leaks or stoppage. Inspect airplane in,oeneral for security of all bolts, nuts, screws, etc. Check the battery. D. 50-HOUR lNSPECTIONGUIDE Complete all steps in the 25-hour inspection plus the following: Engine: (Refer to Lycoming Operator's Manual for other 50-hour inspection items.) Drain oil; inspect and clean screens. Check engine for oil leaks. Check ignition harness for fray, wear, etc. Check throttle, carburetor heat, mixnrre, and propeller governor control for general condition, travel, and free operation (M20C D). Inspect power boost control on M20E models. Check engine mount structure and en~ne rubber dynafocal mounts. Check exhaust stacks for general condition. Check engine baffles for wear or cracks. Check fluid in brake reservoir. Check battery and cables. Check cowl for cracks, loose or missing screws, etc. Propeller: Remove and inspect spinner. Check propeller for oil leaks and general condition. Inspect blades for nicks and cracks. Clean and reinstall spinner. Cabin: Check parking brake cylinder for leaks. Check trim operation. Check cabin door and pilot window for damage and proper operation. Check cabin, navigation, instruments, and landing lights. Check fuel-selector valve For proper operation. 10-2 Island Enterprises Landin,o Gear: Check tires for freedom from escessive ~ear and proper inflation. (Refer to Section I page 1-5.) Check for general condition. Check collars and bolts for damage (Refer to Section V-G). tv`ing: Check surfaces and rips for danlaage. Check ailerons, aileron attachments, and bell cranks for damage and operation. Check flaps and attachments for damage and operation. Lubricate controls as directed in Fi~re 2-9. Fuselage and Empennage: Check stabilizer, fin. and rudder surfaces for dama,oe. Check rudder and elevators for proper attachment. Lubricate controls and trim systems as directed in Fi~re 2-9). E. CZ~DE Perform all steps in 25-and 50-hour inspection plus the following: En,oine: (Refer to Lycomin,o O_Derator's ~Ianual for other 100-hour inspection items.) Remove en,oine COwl and clean engine. Perform a hot engine differential con7pression check. Check and.'or re-place siDark plugs as req~iired. Check ma,oneto points for proper gap. Reset or retime if necessary. Clean fuel strainers and check fuel system for leaks. Check vacuum pump. Check condition of flex fuel lines. Check en~ine and electric fuel pumps for proper operation. Flush battery bos. Remove and check e?chaust stacks and heater muff. Propeller: Rotate blades and check for tightness. Visnafly inspect hub parts for cracks. Check propeller mounting bolts for 60-70 foot pounds of torcIue. Check sDinner and bulkhead for cracks and general condition. Check f~r adequate grease level in hub. Cabin: Remove instrument access panels. Check control and linkage. Check instruments. lines. and attachments. (Check vacuum filter on all 1966 and subsequent models.! Check uDholstery for tears. Check sears. belts, securing brackets and bolts. Landing Gear: Remove and repack rJheel bearin~. (Refer ro Figure 2-9 for recommended lubricant.) Check brake shoes and discs for wear. Check brake lines. Check wheels for ChecZi,oear doors and attachments. Check nose gear steering-control linkage and travel. Check shock discs (Refer to Section V-G). Check 3f20D gear fairings. REVISED NOVEMBER 1966 10-3 Island Enterprises Check tire pressure (Refer to Section I. paXe 1-5,. Lubricate in accordance with Figure 2-9. Check and rig gear (Refe: to Section V-F.). Wing: Remove inspection plates and fairin,os, and check wing for general condition (Refer to Fi~re 10-1.). Check fuel sells for leaks. Check wing-attach bolts for security. NOTE: A reasonable amount of care should be exercised wheninstallingthedimpled inspection plates on the wings of those airplanes having dimpled screw holes in the wing skins. The use of improper screws or over-torcIuin,o of screws is not recommended as this could result in cracking of the ~in,o skins in the dimpled area, Fuselage and Empennage: Check stabilizer bearings, bungees, and horns for damage and proper operation. Check rudder, horns, and attachments for damage and proper operation. Check trim mechanism. Check bulkheads and stringers for damage. Check electrical wiring, loops, loopmounw, and antennas. Check fuel lines. valves, and gages for damage and proper operation. Lubricate in accordance with Fi~re 2-9, F. OVERLIMITS INSPECTIONGLrIDE If the aircraft has been operated so that any of its components have exceeded their maximum opera- tional limits, check with the appropriate manufacturer's manual. G. CHECK Following the 50- and 100-hour inspections, start the engine and check the following items for proper functioning: Check fuel pump and fuel tank selector valve. Check fuel cpanrity and pressure gages. Check oil pressure and temperature gages. Check generator output. Check manifold pressure. Check operation of carburetor heat control. (Inspect power boost control on h120E F models.) Check parking brake. Check gyros for noise and rough operation. Check cabin heater operation. Check magneto switch for grounding at idle RPSI. Check magneto rpm variation (~claxlmum allowable variation is 50 RP~I). Check throttle operation. Check propeller for smoothness of operation. Check propeller governor action. Check radio operation. Check engine idle at 650 rpm. GENERAL: See that aircraft conforms to FAA Aircraft Specifications 2~3. See that FAA Airworthiness Directives have been complied with. See that Manufacturers' Service Bulletins have been complied with. See that aircraft logs and certificates are in proper order. See that the Weight Balance Record is up to date and in the aircraft. See that the Owners Manuz1(1967 and subsequent editions) or the Airplane Flight hianual is complete and in the aircraft. 10-4 REVISED NOVEMBER 1966 Island Enterprises H. ELECTRIC GEAR. INSPECTION (OPTIONAL INSTALLATION) Raise aircraft on jacks to allow operational testing of both the electrical and emergency gear ex- tension systems. (Refer to Section V-R.). An 80 mph air pressure equivalent must·he applied to the pitot tube orifice to activate the airspeed pressure switch to permit retraction of the gear. Attach a Ii-inch length of 3/8-inch plyable rubber hose eurgicaltubing) over the pitot tube end and pinch the open end of the tube with a cotter pin. Rotate the coffer piri zmtil the compressed air within the rolled tube activates the airspeed pressure switch (located in the cabin near the hydraulic reservoir). Then raise the gear electrically. Refer to page 5-23 for emergency gear extension instructions (Manual Operation of th~ Electrical Landing Gear System). Test emergency gear extension. Do not retract the gear with the emergency handcrank; to do so will damage the flexible drive shaft. Thoroughly inspect and lubricate both the electrical and emergency gear extension systems (See Lubrication Diagram, Figure 2-9 for proper lubricant) The drive connector should be removed from the actuating motor and inspected for a worn or stripped f~male spline. Clean and Lubricate the motor worm gear. Test the drive connector to check for proper functioning. NOTES If the pilot experiences difficulty with gear extension or retraction, ~he gear system should be lubri- cated and the malfunction corrected before the next flight.- Raise the aircraft on jacks, locate and correct the trouble, and cycle-test gear operation. Refer to page 5-23, Section H, paragraph 3 for periodic lubrication and inspection specifications for the electric gear system actuator. Always make certain the handcrank is fully disengaged before operating the gear electrically. In trouble shooting the system, remember that a binding or maladjusted gear door may overload the actuating system. Remove the belly panels to examine the knife disconnects under the floor boards for loose or faulty connections. An electrical overload in the system can be discovered by connecting an ammeter in the motor circuit (red wire leading from the actuating motor to the electric fuel pump circuit breaker) beneath the floor boards. Open the red wire knife disconnect and connect the ammeter poles to the disconnect terminals. During gear extension, the ammeter should read 15 to 18 amp; during retraction, 25-30 amp. An amperage reading exceeding the max- imum indicates a faulty motor or electrical circuit and/or a binding in the gear action due to impro- per rigging or misalignment of the gear actuator and its mounting bracket. Dual waroi~ horns (1967 ON models) replace the landing gear-throttle warning horn and prestail indicator installed on 1962-1966 models. The low-pitch, interrupted (beep), 100 CPM horn is wired to the landing gear-throttle switch. The high-pitch, continuous, 2000 CPS warning horn is wired to the prestall warning switch. REVISED OCTOBER 1975 10-5 Island Enterprises FIGURE 10-1 ACCESS PANEL REMOVAL DIAGRAM (100-MOOR INSPECTION) 2 3 I /1S\ 4 6 5 6 6 NOTE: M20F access panel locations are the same as M20E. 7 7 f\ 14 13 12 11 9 8 11 12 13 14 oo oo C10 C3I3 t7Clo 11 10 8 11 C> 1. COHLING-Engine access. 2. ACCESS DOOR-Electrical storage battery (M20C&D) 3. ACCESS COVER-Flight instruments, hydraulic fluid reservoir and parking brake valve, PC rate gyro (1966, M20CgE) NOTE: The turn coordinator replaces the rare gyro and turn and bank indicator on all models 1967 on. RNISED NOVEMBER 1966 10-7 Island Enterprises 4. ACCESS COVER-Electrical storage battery (M20E), PC gyro and servos, pneumatic step, con- trol tubes, trim guide blocks. 5. FAIR1NGS-Empennage attach bearings, trim jack screw. 6. INSPECTION COVERS STINGER-Control bvngees, elevator and r'udder stop adiustmenrs. 7. EXHAUST CAVITY FAIRINGS-Electric boost pump (1965 Models On), selector valve and sump drain, fuel lines, control tubes and bungees, broke cylinders and lines. 8. ACCESS PANELS-Control rubes, main spar, flap indicator cable. 9. INSPECTION COVER-Hydraulic flap pump, stabilizer trim stop indicator adjustment. 10. INSPECTION COVER-Control rubes g guide blocks, hydraulic flap cylinder, flap indicator cable. 11. INSPECTION COVERS-Wing attach, control tube guide blocks. 12. INSPECTION COVERS-Main gear retraction spring. l3. INSPECTION COVERS-Control tube guide blocks. 14. INSPECTION COVERS-Aileron bellcranks and stop ossemblies, control tubes. FIGURE 10-2 POWER BOOST DOOR SEAL INSPECTION DIAGRAM (M20E) I 1 O O 9.99.-.9-\ INSPEtTFOR TIGHT SEAL d 'f ~e oC~I o O O O O O CAUTION: To prevent engine damage during ground or dusty air operation, induction air through the Ram Air Scoop must be shut off completely so that the engine is forced to receive its air through the filter. Therefore the Seal around the Shut-Off Door must be INSPECTED REG- ULARLY FOR LEAKS to insure that unfiltered air cannot bypass the door when the Power Boost Control is in the "OFF" position. 10-8 Island Enterprises (For Company Use Only) SRR No. Probable Cause of Mal- IWOONEY A/RCRAFT, /NC. function: Confirmed O ,~hP'' KERRVILLE. TEXAS Unconfirmed O UNSATISFACTORY REPORT Model Serial No. Beg. No. Geographical Location IEy state or country) Engine Model SerialNo. Propeller Model Serial No. Total Time Since Overhaul Total Time on Airplane Total Time on Malfunctioning Part Part No. (Mooney) Manufacturer (if other than Mooney) Model No. Iif vendor part) SerialNo. (if vendor Part) Rarranty Replacement Yes C7 No n Airplane Owner's Name Address Brief Narrative of Ma~function (or accident) Probable Cause of Malfunction Corrective Action Taken Date Signature Mooney Rep. n SerticeCenter 1Z! Distributor rj Owner C] Dealer O Pilot I I ENG.FORM109 Island Enterprises SHEET N0, 1 spshP~t MOONEY M208 M20C M20D M20E M20F 100-HOUR INSPECflON GUIDE Date...... Ouner's Reg, No...... l...... A/C Serial ~ib...... Aircraft tach, time...... Hrs. Date of last periodic...... Engine Model and Serial ~b...... Prop design and Serial No...... Engine time...... l...... hrs. Brand of oil and weight used...... i. Is approved owners or flight manualin aircraft? Yes No Current and in proper condition? Yes No Are current log books in aircraft? Yes No Current and in proper condition? Yes No 3, Is Registration Certificate.in aircraft? Yes No Current and in proper condition? Yes No -t. Is Airworthiness Certificate in aircraft? Yes No Current and.in proper condition? Yes No 5. Is all factory service information complied with? Yes No 6. Are all applicable FAA.4irworthiness Directives complied with? Yes No 7. Is H'eight Balance Record current? Yes No ESGINE SECTION: (Refer to Lycoming Operator's Manual and Mooney Mechanic's Inspector's Service Maintenance Mannal,) Initials Initials i, Remove and clean engine cowling and baffling; inspect for cracks and wash engine 2, Perform a hot engine differential compression check: cyl. read- ing 1. 2. 3, 4, 3, Lubricating System (Refer to Lycoming Operator's Manual.) a. Drain sump and change oil filter (if installed) b, Remove pressure and suction screens. Check for metal c, Clean and inspect screens. Reinstall and safetjr screens d, Check engine for oil leaks (note correct)- e, Inspect condition of oil cooler f, Service engine with recommended lubricating oil (Refer to Mooney S M Manual,) Ignition System (Refer to Lycoming Operator's Manual.) a, Inspect spark plugs, replace or clean and regap b, Inspect ignition harness for general condition and freedom from fraying or chaffing c. Inspect magnetos and points; check magneto-timing _5. Electrical System (Refer to Mooney S gr ;M Manual.) a. Inspzct battery for security, battery box for corrosion, and vent for obstruction b. Inspect·gznerator and accessories c. Inspect electrical components and wiring REVISED NOVEMBER 196~ Island Enterprises SHEET NO. 2 sA~PLE d. Inspect starter and starter drive; lubricate starter drive. (Refer to LSlcoming Operator's Manual and Figure 2-9, Mooney S&M;Llanual)- e. Inspect landing light and navigation lights for and operation f. Inspect panel lights and dimming system for operation 6. Fuel System, M-20B,C,D (Refer to Mooney S 8; M Manual.) a. Inspect carburetor, clean screens, and check fuel flow b. Inspect carburetor heat system for leaks and proper operation c. Remove, clean, inspect, and reoil air filter d. Inspect carburetor airbox and induction system for condition e. Inspect fuel selector valve for operation and proper pointer indication f. Operate boost pump; check pressure and all lines for leaks g. Clean electric fuel pump screen (1963 and previous models) h. Drain fuel sumps and fuel selector valve (R L tanks) 6A. Fuel System, M-20E (Refer to Mooney S M Manual.) a. Inspect fuel injection system, clean screens, and injector nozzles (Refer to Bendix Service Manual.)-- b. Check power boost system for proper operation and door seal for leaks c. Remove, clean, and inspect dry-air filter d. Inspect air induction system and alternate-air valve e. Inspect fuel selector valve for operation and proper pointer indication f. Operate boost pump; check pressure and ail lines for leaks g. Drain fuel sumps and fuel selector valve (R L tanks) 7. Remove heater jacket and inspect exhaust system for leaks and cracks. Remove exhaust cavities and inspect area 8. Inspect fire wall for proper sealing and freedom from cracks 9. Inspect engine mount, bolts, and rubber mounts for security 10. Lubricate engine controls and inspect for security, full travel, and free movement 11. Lubricate cowl flaps and inspect for proper opening and operation 12. Remove propeller spinner and check for cracks and general condition 13. Inspect propeller hub for grease leakage; check hub bolts and mounting bolts for proper torque; inspect blades for cracks, nicks, and dents; lubricate as needed (Refer to appropriate manufacturers' handbooks.) AIRFRAME SECTION (Refer to Moonev Service Maintenance Manual.) 1. Inspect exterior and interior of aircraft for general condition, collision damage, loose rivets, dents, and corrosion 2. Inspect wings and empennage for general condition, collision damage, loose ri~ets, dents, and corrosion 3. Inspect control surfaces for security of attachment, proper rigging, free movement, collision damage, loose rivets, dents, and corrosion 4. Lubricate flight control system guide blocks, hinge points, rod end bearings, and bell cranks (Refer to Mooney S M Manual, Figure 2-9.) 5. inspect all wing, fuselage, and empennage drain holes for obstruction 6. Inspect empennage trim system for proper operation and rigging. Lubricate in accordance with Figure 6-8 in ~koney S 51 Manual 7. Inspect flap system LM-20B, mechanical; M"OC,D,E, hydraulic) for proper operation and rigging. Lubricate in accordance with Figure 1-9 in Mooney S M Manual 8. Inspect flight instmments, filters, and vacuum system for proper operation, marking, and condition. Clean vacuum air filter (1966 and subsequent models) Island Enterprises SHEET NO, 3 samP~ 9. Inspect cabin lights, circuit breakers, and electrical components for proper operation 10. Inspect PC system components for security, leaks, and proper operation. (Refer to Mooney S g: M Manual) 11. Inspect vacuum step for security and proper operation. (Lubricate in accordance with Mooney S M Xlanual) 12. Inspect wing interior in fuel tank area for fuel leaks, fuel tanir vents for obstruction, and fuel filler caps for security and proper operation 13. Inspect cabin and baggage doors for condition, proper operation, and- sealing Inspect windshields and windows for cracks, crazing, scratches, and distortion 15. Inspect seats and seat belts for security, proper operation, and condition 16. Inspect compass and compass deviation card forproper indication and compensation. (Refer to Mooney Bulletin No. 8 ~Serv.ice Instruction M20-23~. 17, Inspect radio equipment for proper installation and operation 18. Inspect cabin for proper sealing LANDING GEAR OPERATIONCHECK (Refer to Moonev S M Manual.) 1. Raise aircraft on jacks. (Refer to iMooney S M Manual.) Inspect brakes, hydraulic brake cylinders, and hydraulic system for leaks and general condition 3. Remove wheels, inspect, repack, reinstall, and safety. Lubricate brake guide pins using Silicone-base lubricant. Check wheels for free rotation and proper brake action. (Refer to Mooney S M Manual.) 4. Lubricate and inspect landing gear pivot points and moving parts. (Refer to Mooney S M Manual, Figure 2-9.) 5. Manual gear retraction system: check operation, rigging, gear warning system (lights hem), down-lock preload, and doors for proper closing. (Refer to Mooney S& M Manual.)- 5A. Electric gear retraction system:. check operation, rigging, gear warning system (lights horn), up-lock mechanism, air-pressure safety switch, down-lock preload, and doors for proper sequencing and sealing 5B. Lower gear with the emergency gear extension system. Dd not attempt gear retraction using emergency system. (Refer to Mooney S M Manual.) 6. Inspect shock absorbers (main nose gears) in accordance with Figures 5-12 or 5-13, Mooney S M Manual 7. Fixed gear: inspect landing gear fairing (M-20D)- 8. Check operation of stall warning system 9. Check air seals in flap and wheel well areas 10. Operate flap system. Service hydraulic reservoir. (Refer to Mooney S g,M Manual for fluid specifications.) POST-INSPECTION OPERATION CHECK (Refer to Mooney Owner's Manual.) 1. Check propeller governor operation with engine running at 2000 rpm and pitch control at low pitch thigh rpm); when propeller control is pulled out to high pitch (low rpm), engine speed should decrease at least 500 rpm 2. Check ease of operation for all engine controls with engine running 3. Check generator output indication ·1. Check oil pressure indication 5. Check fuel pressure indication Island Enterprises SHEET NO. 4 SAIPL~ 6. Check fuel quantity indication 7. Check cylinder head temperature indication 8. Check oil temperature indication 9. Check idle rpm, idle mixture, and idle cutoff- 10. Check propeller pitch through range 11. Check cabin and panel lights 12. Check radio operation 13. Check autopilotoperation 14. Check magneto drop and ground 15. Check brake operation 16. Check fuel selector valve operation 17. Test vacuum warning lights and instruments for proper operation 18. Flight check gear-up warning horn at 12" manifold pressure 19. Flight check aircraft rigging and PC system for proper operation 20. Make a cabin ventilation and heating system carbon monoxide check Island Enterprises SECTION PAINTING AND PREVENTION OF CORROSION Island Enterprises SECTION XI PAINTING PREVENTION OF CORROSION A. GENERAL This section lists paint materials and recommended painting procedures. Corrosion control tech- nicFres are also discussed along with suggested procedures for zinc chromating internal airframe surfaces. E3. PAINTING The exteriors of all new lu120 series aircraft are painted with acrylic enamel. This finish should be freplently cleaned with an aircraft-type washing compound when exposed to salt air or an atmosphere having corrosive fallout. Aircraft should be hangared when not in use. 1. Materials. a. 83319 (Code 033650) solvent-type cleaner, Dupont Prepsol b. Cheesecloth; Sandpaper, 3M, 180-400-600 grit. c. T-657 cleaningsolvent 309·6 (Code 035210) wash thinner. Enmar d. Body puny or aerodynamic filler (Taylor Art Plastics, Flax-Bond "C" or 3M Co. Flex) e. EX2858A (Code 034150) filler/primer, Enmar Gray MX22B (Code035130) dopeandlac~erthinner f. EX2016G (Code 034175) vinyl-type zinc chromate primer, Enmar EX2016G (Code 035120) vinyl-type reducer g. 82A25414 (Code 030730) exterior base acrylic enamel, Enmar Ermine White T1866A (Code035170) acrylicenamelthinner h. Refer to Table 8 for exterior color coat material callout. i. Refer to Table 8 for exterior trim material callout. Factory recommended replacement exterior trim finish: 61P-34929, P-38502 Enmar Sierra Gold (syrithetic finish) C-85 thinner Do not use sealcoat with synthetic finish. j. T1411 (Code 035150) burn-down thinner k. 271125414 (Code 033550) laccluer, Enmar Ermine White (tubular steel structure) MX22B (Code 035130) dope and lacc[uer thinner 8585A (Code 034105) low moisture sensitive zinc chromate primer i. EX-1707 (Code 033130) acid-resistant black paint (banery case and exhaust areas) MX22B (Code 035130) dope and lacquer thinner m. Refer to Table 8 for interior trim material callout. ii-i Island Enterprises 2. Procedures a. For urliformity of finish appearance, prepare only entire skin panels for repainting. First, clean the area to be repainted with the solvent-type cleaner. Wipe on, then wipe off cleaner with cheese cloth or clean towels until surface is dry. Second, sand areas to be painted as needed-start with No. 400 grit (wet or dry) and finish with 600 to 800 grit. Third, reclean entire area to be painted with the solvent-type cleaner, wipe clean, and mask-off adjoining areas that will not be painted. b. To fill dents, use a flexible plastic welding compound (bodyputty or aerodynamic filler). Carefully follow instructions printed on the container. c. All spray-applied paints must be mixed in a one-to-one proportion(50-50) with their ap- propriate thinners. When using a large compressor unit and re,oulator, maintain a 60 PSI spraying pressure and be sure intake air is properly filtered. A portable spray pot should be set to maintain a 40 PSI minimum spraypressure. Work only in a dust and moisture controlled painting area. d. Use a face respirator to prevent inhalation of paint dust. It is recommended that the work- man apply a li~t coat of vaseline to his hair and exposed skin to allow easy removal of paint stains with a mild soap solution e. Always test-spray a new paint mixture on masking paper before proceeding with the appli- cation. Hold the spray nozzle eight to ten inches from the surface. Spray in cross patterns with verticdl stroke movements first and then withhorizontal movements over the same area. f. Apply vinyl-chromate primer mixed with vinyl-type reducer to newly installed unpainted skins. Apply one coat of appropriately thinned gray primer (Enmar filler) to previously painted surfaces that have been properly prepared for repainting. Allow primer to dry run- free, then spray three coats of the properly mixed finish paint. g. All acrylic enamel paints have a tendency to "orangepeel" when sprayed too close to the panel or when the paint viscosity is too high. The ~tddition of an equal pan of burn-down thinner to the thinned finish paint will eliminate orange peel effect due to improper thinning. h. Apply three coats of white base and/or color finish allowing three to five minutes between coats depending upon weather conditions. Allow five to ten minutes between coats in cold, dry weather; in humid weather, each coat should dry in fifteen minutes. i. Do not thin acid-resistant black paint or exterior finish touch-up paint for brush-on appli- cation. Use a small round watercolor brush trimmed to a point for ap~lication of undiluted touch-up paint to small scratches and bare spots. A handy rack for touch-up paint storage can be made from babyfood jars mounted in a wooden rack. 11-2 Island Enterprises TABLE 8 EXTERIOR PAINT CHART YEAR I MODEL I PART NO. DESCRIPTION LOCATION 1962 M-20C 82A-28378 TITIAN RED, Acrylic Enamel Exterior Trim 1962 M-20C 82A-27633 BLUE METALIC, Acrylic Enamel Exterior Trim 1962 NI-ZOC 82A-28161 DARK GOLD, Acrylic Enamel Exterior Trim 1962 M-20C 82A-27630 BLUE METALIC, Enamel Exterior Bottom Acrylic _ 1962 M-20C 82A-28303 ROMAN RED, Acrylic Enamel Exterior Bottom 1962 g 1963 M-20C 27H-20800 SPICE BROWN, Acrylic Enamel Interi4r Trim )962 8 1963 M·ZDC 82A-26183 LIGHT GOLD, Acrylic Enamel Exterior Bottom 1963 M-20C 82A-29626 GUNMETAL, Acr2lic Enamel Exterior Trim 1963 M-20C 82A-29629 FROSTED TURQUOISE, Acrylic Enamel Exterior Bottom 1963 M-2DC 82A-29744 FROSTED GREEN, Acrylic Enamel Exterior Bottom 1963 M-20C 82A-29745 FROSTED COPPER, Acrylic Enamel Exterior Bottom 1963 M-20C 828-29801 FROSTED RED, Acrylic Enamel Exterior Bottom 1963 M-~OD 82A-29801 FROSTED RED, Acrylic Enamel Exterior Bottom 1964 M-20C,DgEI 82A31495 METALLIC ORANGE, Acrvlic Enamel Exterior Bottom 1964 M-20C.DgEI 82A-32014 SILVER BLUE, Met. Acrylic Enamel Exterior Bottom 1964 M-20C.DgEI 82A-32015 LIGHT EMERALD, Met. Acrylic Enamel Exterior Bottom 1964 M-20C.DgEI 82A-32016 BERLY BLUE, Met. Acrylic Enamel Exterior Bottom 1964 M-20C.DgEI 27H-23455 SAND BEIGE, Acrylic Lacquer interior Trim 1964 M-20C.DgEI 27H-20800 SPICE BROWN, Acrylic Lacquer Interior Trim 1964 M-20CgD 82831885 CANYON GOLD, Met. Acrylic Enamel Exterior Trim 1964 M-20E 82A-32264 DARK CANYON GOLD,EAet. Acrylic Enamel Exterior Trim 1965 M-2DC.DgEI 828-34923 YELLOW, Acrylic Enamel Exterior 1965 M-20C.DgEI 82834924 BLUE, Acrylic Enamel Exterior 1965 M-20C.D&EI 828-34925 RED, Acrylic Enamel Exterior 1965 M-20C.DgEI 828-33929 SIERRA GOLD, Acrylic Enamel Exterior i966 M-2DC.DgEI 828-37781 GREY, Acrylic Enamel Exterior 1966 M-20C.DgEI 828-37778 RED, Acryiic Enamel Exterior 1366 M-20CgD 82B37780 BLUE/GREEN, Acrylic Enamel Exterior 1966 M-20E 828-37775 BRILLIANT BLUE, Acrylic Enamel Exterior 1966 M-20E 828-37776 BRILLIANT GREEN, Acrylic Enamel Exterior 1967 MZ0C,E,gFI 82834925 POPPY RED Acryiic Enamel Exterior 1967 M20C,E,gq 82839276 BRITE ROSE Acrylic Enamel Exterior 1967 MZOC,E, 82839283 BRITE ORANGE Acryiic Enamel Exterior 1967 MPOC.E.&q 82839295 GOLD Acrylic Enamel Exterior Trim 1967 M20C,E,g 82840054 MOONEY WHITE Acrylic Enamel Base Color 1967 MPOCIEI& 82B37781 GRAY Acrylic Enamel Exterior Trim MISCELLANEOUS PAINTS 8 MATERIALS ALL ALL 828-25414 WHITE, Acrylic Enamel General Exterior ALL ALL MX-lld3 OVERCOAT, I General Exterior ALL ALL MX-22B THINNER, Lacquer General Exterior ALL ALL MIL-5041 BLACK. Non-skid Wing Walld General Exterior ALL ALL 6633 TAPE, Gold Decorating General Extnr;or ALL ALL r630 TAPE, Chrome Decorating General Exterior ALL ALL MX-144B BLACK, Temporary Marking ALL ALL MiL-D-8585A PRIMER. Zinc Chromate Structure ALL ALL EX-1707 BL4CK, Acid Proof Structure ALL ALL E-6889 PRIMER, Zinc Chromate (spray can) Structure ALL ALL EX-2016G PRIMER, Zinc Chromate (vinyl type) Structure ALL ALL 1 =23-622 BLACK, Lacquer Structure ALL ALL EX-1858-A-6q PRIMER. Light Gray Structure ALL ALL 1 T-6073 THINNER, Zinc Chromate Structure 1965 M20t.D,gE! EX-617Cj BEIGE Baked Enamel Interior Trim 1965 8 1966 M20t,D,gEI n"4205 LAREDO TAN Lucite Interior Trim 1966 M20t,D,gEI 27H-25988 ECRU Lacquer Interior Trim 1966 MZOC,D,gEJ 27H-3808 GRAY Lacquer Interior Trim 1966 M20C,D,&EI 27H-24697 CARPET BEIGE Lacquer Interior Trim and NOTE: 1967 1966 M20D points and materials are identical. REVISED NOVEMBER'1966 11-3 Island Enterprises C. CORROSION DETECTION PREVENTION Most metalic fabrication materials are susceptible to corrosion. Corrosion may occur an aircraft in any climate, but it will be a problem more often in areas where the aircraft is exposed to salt air or high humidity, or where there are industrial contaminants in the armosphere. The aircraft should be Inspected frequently to detect and correct corrosion before serious damage occurs. I. Types of corrosion. Corrosion normally appears in one or more of four forms. Eacb type of corrosion can be pre- cluded or controlled by a preventative maintenance program. a. Chemical corrosion Chemical corrosion normally occurs where battery acid or exhaust gases come in contact with metalsurfaces. A few simple precautions will prevent chemical corrosion. 1. Be sure that the battery vent is free from obstruction at all times. 2. All scratches and worn spots, found in areas painted with acid-resistantpaint, should be repainted at once. 3. If acid is spilled on metal surfaces, flush the entire area with sodium bicarbonate add water. The solution should be rinsed away at once and the area dried by driving all water from crevices with an air hose before wiping the surface dry with a clean cloth. 4. Frequently clean exhaust gas deposits from metal surfaces. b. Local-cell corrosion Local-cell corrosion is easy to detect. On baremetal surfaces, in an early stage of develop- ment, it appears as a light, wfiitish powder deposit. Surface pits warn of advanced local- cell corrosion. On painted surfaces, the first indication of corrosion will be evidence of paint blistering. Any form of corrosion should be removed at once upon detection. If it is necessary to re- move paint, only an approved aircraft paint remover should be used. Care should be taken that paint removing substances are not allowed to remain in metal crevices, for this will cause further corrosion. Turco 2662(3 or 3002 will remove corrosion and treat the metal surface in one application. c. Concentrationcell corrosion. Corrosion forming under rivet heads, along faying surfaces, or at skin to longeron contact surfaces is called concentration cell corrosion. Detection recFdres close inspection. Rivets must be removed and skin laps must be separated to remove concentration cell corrosion. Use aluminum wool soaked in kerosene to scour corrosion deposits from the surface before painting both fayin,a surfaces with zinc chromate primer and reassemblying. d. Galvanic corrosion Galvanic corrosion sometimes occurs between dissimilar metals such as stainless steel and aluminum. To remove this form of corrosion, separate the pans, remove the corrosion, and paint both surfaces with zinc chromate primer before reassembling. Further recommended procedures for corrosion control areoutlined in Turco Products Tech- nical Data Bulletin g184. Write Turco Products. inc., P.O. Box 1055, Wilmington, California. 11-4 Island Enterprises 2. Hints onpreventingcorrosion. a. Thoroughly examine unpaimed metal surfaces at inspections and check corrosion when found. Carefully examine seams, lap joints, and crevices wheremoisture or dirt can collect. Areas exposed to exhaust gases require frequent inspection and cleaning. b. Corrosion may attack metal even though the surface is painted. Inspect painted areas for a blistered or scaly appearance that warns of corrosion below the paint layer. c. Use only aircraft detergents to wash the exterior airframe. Cover vent scoops whenthe aircraft is being washed. Rinse the exterior after exposure to salt air or industrial fallout. d. Since moisture promotes corrosion, areas where water is apt to collect must be inspected thoroughly and frequently. Use an air hose to drive water from crevices before wiping the exterior surface dry after washdown. e. Hangar the aircraft when not in use. f. If battery acid is spilled on any part of the aircraft, wash the area immediately with a solu- tion of sodium bicarbonate in water. Rinse with water and dry with clean towels. 3. Zincchromating. Zinc chromating internal surfaces of the airframe will greatly retard corrosion. However, chromating will not eliminate the necessity of periodic inspection aimed at detection of trouble s_aots, especially in those areas where it is impracticableto apply zinc chromate (skin laps, fayings, etc.). If deep corrosion is found, it should be removedby sandingwith emery cloth of approximately 320 grit. Aluminum etching compounds are not recommended for corrosion removing, because they cannot be readily neutralized. a. Materials i. Cleaning solvents a. T-657 cleaning solvent-Turco Products, Inc., 6135 South Central Avenue, Los Angeles, California. b. ,U394 wash thinner Enmar, Inc., 25th N.Y. Avenue, Wichita, Kansas. 2. Zincchromate a. zinc chromate primer (Mil. Spec. P-8585A)-Enmar, Inc., 25th N.Y. Avenue, Wichita, Kansas. 3. Safetymixingcan a. ~10308 Justrite Manufacturing Co., Chicago, Illinois. b. Procedure 1. Cleaning a. Pour a portion of the cleaning fluid into the safety mixing can. b. Wipe the area to be cleaned with a clean rag dipped in the cleaning fluid. c. Wipe the cleaned area with a rag dipped in the cleaning solvent. The entire area to be painted should be cleaned before application of the primer. CAUTION: Wipe solvent is toxic and flammable. Do not smoke within 25 feet of the exposed solvent. Force air through the painting area and use only explosion-proof lights. 11-5 Island Enterprises SHOP NOTES 11-6 Island Enterprises APPENDIX Island Enterprises SERVICE SHOP TOOPS EQUIPMENT I. AIRFRAME SOURCE TOOL PART NUMBER Commercial Jack and stand Mooney Distributors Gear retractioq spring replacement tool 8186 Mooney Distributors Landing gear retracting truss torque tool 010011 010008 Mooney Distributors Travel boards 010013001-R~udder 01001i0001-Elevator 010007001-Flap Mooney Distributors Shock disc replacement tools ME 120 ME 121 Commercial Torque wrench TQ-51-A (or equiv.) Peterson Mfg. Co., Wide-jaw vice grips for control surface De\rc'itt, Neb. trimming (See Figure 6-3 in Mooney Service Maintenance Manual) Brittain Industries Positive Control system test kit TS-100 Mooney Distributors AMP connector kit Mooney Distributors Solderless terminal tool (3 sizes available) Commercial Battery charger Commercial OHM meter Commercial k~lP meter Commercial Grease gun Tools for sheet metal work: Commercial Rivet gun Commercial Air drill Commercial Cutters Note: No. 5 and 6 huckrivet tool for landing gear conversion or wing spar repair can be obtained from Aircraft Tools, Inc., 9030 Bellanca Ave., Los Angeles 45, California. II~ ENGINE AND ACCESSORIES Commercial Differential compression tester Commercial Spark plug cleaner Commercial Gap setting tool Commercial Growler Lgcoming Cylinder base nut wrench 64943-64942 Lycomirlg Valve spring compressor 1130-B Lycoming Ring compressor Bendix. Timing kit (Bendix) 11-8150 Bendix Timing light (Bendix) Model A1D (or equiv.) Bendix Piston position indicator Island Enterprises MOONEY AIRCRAFT FART NUMBER CROSS REFERENCE INDEX New No. Old No. New No. Old No. New No. Old No. 01 0000 2286 140000 3522 150000 8705 010001 8188 140001 3521 150001 8522 010002 2312 140002 3519 150004 6458 010003 3302 140003 3518 150011 8519 010004 3149 140004 3028 150012 8520 010005 8577 140005 3047 150013 8521 010006 3301 140006 3057 010007 8663 140007 3323 010008 8444 140008 3438 010009 8443 140009 3439 010010 8441 140010 3505 160000 8015 010011 8442 140011 3506 160001 8551 140012 3507 160002 8552 140013 3508 160003 8654 140014 3509 140015 3510 110000 8670 140016 3511 110001 8585 140017 3512 200000 8600 110002 7344 140018 3513 110003 7345 140019 3515 110004 7274 140020 3527 110009 8610 140021 3652 210000 2182 140022 -3653 210001 2169 140023 3654 210002 2170 140024 3655 210003 2167 140025 3656 210004 2168 120000 8062 140026 3657 210005 2171 120001 8122 140030 3664 210006 2172 120002 8282 140031 3666 210007 2173 120003 8704 140033 3668 210008 2174 120004 8531 140034 3669 210009 2226 140035 7083 210010 2227 140036 8527 210011 2228 140037 8536 210012 2229 140038 3045 210013 2198 130000 8300 140039 3397 210014 2199 130001 8318 140062 3299 210015 2221 130002 8319 140063 3660 210016 2222 130025 8325 140064 3662 210017 2233 130026 8326 140065 3667 210018 2241 130027 8327 140066 8248 210019 2191 130041 8341 140067 3659 210020 2230 130042 8343 140068 3661 210021 2271 130044 8345 140069 8035 210022 2217 130054 8354 140070 8007 210023 2236 130055 8596 140071 3650 210024 2192 130056 8671 140072 3651 210026 2195 130057 8532 140073 3658 210027 2190 130058 8310 140074 3663 210028 2201 130065 8504 140075 3961 130066 8576 140076 3058 210025 2234 Island Enterprises No. New No. Old No. New No. Old No. New No. Old 210029 2211 210085 2303 230004 2292 210030 2210 210086 2309 230005 2293 210031 2209 210087 2310 230006 2295 210032 2208 210088 2301 230007 2297 210033 2207 216089 2300 230008 2289 210034 2206 210090 2304 230009 2296 210035 2205 210091 2280 230010 2308 210036 2204 210092 2281 230011 2175 210037 2223 210093 2284 230012 2177 210038 2193 210094 2250 230013 2178 210039 2202 210095 2270 210040 2203 210096 2267 210041 2194 210097 2231 214042 2189 210098 2238 240000 2248 210043 2184 210099 2235 240001 2160 210044 2188 210100 22~40 240002 2161 210045 2185 210101 223 240903 2162 210046 2187 210102 2214 240004 2163 210047 2179 210103 2323 240005 2164 210048 2186 210104 2220 240006 2245 210049 2224 210105 2249 240007 2246 210050 2225 210106 2219 240008 2247 210051 2244 210107 2181 240009 2268 210052 2216 210108 2277 240010 2269 210053 2218 210109 2274 240011 2298 210054 2213 210110 2276 210055 2165 210111 2275 210056 2166 210112 2307 300000 8017 210057 2212 210113 2313 210058 2242 210114 2326 210059 2237 210115 7302 210060 2251 210116 7231 210061 2252 210117 7232 310000 3011 210062 2253 210118 7252 310001 3016 210063 2254 210119 7273 310002 3032 210064 2255 210120 2232 310003 3037 210065 2256 210121 2315 310004 3038 210066 2266 210122 2243 310005 3039 210067 2257 210123 2258 310006 3052 210068 2259 210124 2518 310007 3053 210069 2196 210125 i31~9 310008 3123 210070 2183 310009 3124 210071 2215 3100i0 3150 210072 2260 310011 3155 210073 2261 220000 2180 310012 3159 210074 2262 220001 2288 310013 3161 210075 2263 310014 3162 210076 2264 310015 3163 210077 2265 310016 3165 2i0078 2272 230000 2200 310017 3166 210079 2278 230001 2294 310018 3167 210080 2279 230002 2290 310019 3169 210081 2282 230003 2291 210082 2287 210083 2285 210084 2283 Island Enterprises New No. Old No. New No; Old No. New No. Old No. 310020 3185 310076 3358 310132 3984 310021 3192 310077 3361 310133 3988 310022 3193 310078 3364 310134 3990 310023 3194 310079 3336 310135 3991 310024 3196 310080 3367· 310136 3992 310025 3197 310081 3368 310137 3995 310026 3200 310082 3369 310138 3996 310027 3212 310083 3370 310139 3997 310028 3214 310084 3371 310140 3524 310029 3215 310085 3372 310149 3359 310030 3216 310086 3373 310150 3360 310031 3217 310087 3374 310151 3213 310032 3218 310088 3375 310152 3263 310033 3219 310089 3376 310153 3985 310034 3220 310090 3377 310035 3222 310091 3378 310036 3227 310092 3379 310037 3228 310093 3380 310038 3233 310094 3381 320000 3520 310039 3236 310095 3382 320091 8257 310040 3237 310096 3384 320004 3261 310041 3285 310097 3385 320005 3128 310042 3286 3101398 3388 320006 3951 310043 3292 310099 3389 310044 3246 310100 3390 310045 3250 310101 3528 310046 3251 310102 3394 340000 3900 310047 3252 310103 3396 340001 3020 310048 3253 310104 3413 340002 3022 310049 3254 310105 3414 340003 3023 310050 3255 310106 3415 340004 3044 310051 3256 810107 3416 340005 3051 310052 3257 310108 3418 340006 3093 310053 3259 310109 3422 340007 3131 310054 3266 310110 3437 340008 3132 310055 3268 3~0111 3483 340009 3271 310056 3300 310112 3486 340010 3272 310057 3310 310113 3494 340011 3274 310058 3311 310114 3429 340012 3275 310059 3312 310115 3530 340013 3276 310060 3318 310116 3543 340014 3277 310061 3319 310117 3953 340015 3278 310062 3321 310118 3955 340016 3279 310063 3324 310119 3956 340017 3280 310064 3325 310120 3957 340018 3283 310065 3326 310121 3958 340019 3331 310066 3321 310122 3959 340020 3347 310067 3328 310123 3973 340021 3348 310068 3329 310124 3974 340022 3349 310069 3332 310125 3975 340023 3455 310070 3333 310126 3976 340024 3456 310071 3352 310127 3977 340025 3488 310072 3353 310128 3978 340026 3525 310073 3355 310129 3979 340027 3526 310074 3356 310130 3981 340028 3531 310075 3357 310131 3982 Island Enterprises Old No. New No. Old No New No. Old No. New No. 6126 340029 3606 340090 3964 350039 3289 340030 3611 340091 3965 350040 3308 340031 3612 340092 3966 350041 3401 340032 3613 340093 3972 350042 3402 340033 3614 340094 3129 350043 3406 340034 3901 340095 3130 350045 3417 340035 3902 340097 3940 350046 3424 340036 3903 340098 3034 350047 3425 340037 3904 340099 3937 350048 3434 340038 3905 340100 3938 350049 3436 340039 3906 340101 3936 350050 3445 340040 3907 340102 3042 350051 3446 340041 3954 340103 3949 350052 3451 340042 3968 350053 3475 340043 3969 350054 3910 340044 3970 350055 3912 340045 3971 350000 3911 350056 3913 840046 3987 350001 3031 350057 3914 340047 3989 350002 3036 350058 3915 340048 3993 350003 3041 350059 3916 340049 3998 350004 3050 350060 3917 340050 3999 350005 3060 350061 3918 340051 3994 350006 3061 350062 3~0052 3500 350007 3062 350063 3919 3920 340053 3501 350008 ~3064 350064 3921 340054 3502 350009 3065 350065 340055 3503 350010 3066 350066 3922 340056 3504 350011 3067 350067 3923 340057 3391 350012 3068 350068 3924 340058 4012 350013 3069 350069 3925 3926 340059 7061 350014 3070 350070 3927 340060 7062 350015 3071 350071 3928 340061 7047 350016 3072 350072 3929 340062 7069 350017 3073 350073 3930 340063 7070 350018 3074 350074 3931 340064 7137 350019 3075 350075 3932 340065 7138 350020 3076 350076 3934 340066 8146 350021 3077 350077 3935 340067 8117 350022 3078 350078 3943 340068 8163 350023 3079 350079 3945 340069 8173 350024 3082 350080 3948 340070 8174 350025 3083 350081 3950 340071 8176 350026 3099 350082 3960 340072 8164 350027 3100 350~83 3980 340073 8505 350028 3101 350084 340074 8506 350029 3104 350085 3986 3485 340075 8529 350030 3106 350086 3498 340076 8376 350031 3108 350087 3334 340077 8240 350032 31-10 .350088 340078 8209 350033 3111 350089 3335 3336 340079 3025 350034 5112 350090 3337 340080 7473 350035 3113 350091 340081 3118 350036 3114 350092 3338 340087 3939 350037 3119 350093 3341 340088 3941 350038 3120 350094 3342 340089 3942 350095 3345 Island Enterprises New No. Old No. New No. Old No., New No. Old No. 350096 3365 410028 4173 440015 4137 350097 4175 410029 4178 440016 4212 350098 4176 410030 4179 440017 4171 350099 6158 410031 .4192 440019 4190 350100 8535 410032 4193 350101 8258 410033 4194 350102 8273 410034 4199 350103 8274 410035 4202 350104 8275 410036 4203 350105 8276 410037 4205 450000 4101 350106 8~77 410035 4211 350107 8284 350105 8285 350109 8286 420000 4102 350110 8279 350111 8283 4104 350119 8034 430000 4103 460000 4105 350120 8231 430001 4152 460001 4151 350121 3267 430002 4157 460002 430003 4162 460003 4158 430004 4164 460004 4159 4160 400000 8601 430005 4165 460005 4161 400001 8602 430006 4166 460006 430007 4167 460007 41.63 430008 4168 460008 4269 4191 410000 4145 430009 4170 460009 4198 410001 4115 430010 4185 460010 4206 410002 4106 430011 4188 460011 4181 410003 4119 430012 4189 460012 410004 4120 430013 4195 410005 4121 430014 4196 410006 4122 430015 4197 410007 4123 430016 4204 470000 3175 410008 4124 430017 4180 470001 3290 410009 4125 470002 3933 410010 -1126 410011 4127 410012 4128 440000 4107 480000 4100 410013 4129 440001 4108 480001 4174 410014 4130 440002 4109 480002 4182 410015 4131 440003 4110 480003 4155 410016 4136 440004 4111 410017 4138 440005 4112 410018 4139 440006 4113 500000 8603 410019 4146 440007 4114 410020 4147 440008 4116 410021 4148 440009 4117 510000 5003 410022 4149 440010 4118 510001 5004 410023 4150 440011 4132 510002 5005 410024 4153 440012 4133 510003 5006 410025 4154 440013 4134 510004 5266 410026 4156 440014 4135 510005 5014 410027 4172 510006 5267 Island Enterprises New No. Old No. New No. Old No. New No. Old No. 510007 5019 540003 5070 560018 5225 510008 5021 54004 5074 560019 5226 510009 5022 540005 5078 560020 5227 510010 5023 560021 5228 510011 5026 560022 5229 510012 5027 560023 5230 510013 5028 550000 8591 560024 5231 510014 5029 550001 5237 560025 5232 510015 5030 550002 5238 560026 5233 510016 5258 550003 8590 560027 5234 510017 5259 550004 8367 560028 5236 510018 5049 550005 8368 560029 5239 510019 5051 550006 8053 560030 5240 510020 5058 550007 8651 560031 5241 510021 5067 550008 8051 560034 5244 510022 5080 550009 8052 560038 5250 510023 5083 550010 8054 560039 5251 510024 5084 550011 8058 560040 5253 510025 5093 550012 8059 560041 5254 510026 5100 550013 8075 560043 5275 510027 5131 550014 8110 560044 5085 510029 5186 550015 8111 560045 8653 550016 8128 560046 5286 550017 8124 560047 5287 550019 8125 560048 5288 520000 5257 550020 8126 560049 5289 520001 5071 550021 8129 560050 8005 520002 5018 550022 8130 560051 5264 520003 5013 550023 8131 520004 5031 550024 8133 520005 5256 550025 8134 590000 3409 550026 8149 590001 3407 530000 5012 550027 8526 590002 3040 530001 5010 590004 3410 530002 5017 560000 5252 530003 5032 560001 5009 530004 5066 560002 5033 600000 6000 530005 5077 560003 5034 600001 6010 530006 5081 560004 5038 600002 6005 530007 5106 560005 5039 600003 6004 530008 5109 560006 5040 600004 6008 530009 5133 560007 5041 600005 6021 530010 5164 560008 5047 600006 6084 530011 5187 560009 5056 600007 6076 530012 5272 560010 5057 600008 6077 530013 5273 560011 5059 600009 6078 560012 5092 600010 6079 560013 5099 600011 6080 540000 5048 560014 5169 600012 6081 540001 5015 560015 5170 500013 6082 540002 5062 560016 5182 600014 6083 560017 5183 600015 6088 600016 6090 Island Enterprises New No. Old No. New No. Old No. New No. Old No. 6438 600017 6091 600073 6229 620008 6199 600018 6092 600074 6231 620011 620012 6405 600019 6093 600075 6235 600020 6094 600076 6245 600021 6095 600W7 6260 630000 6489 600022 6096 600078 6372 630001 6490 600023 6097 600079 6374 6~30002 6371 600024 6100 600080 6383 630003 6365 600025 6101 600081 6384 630004 6362 600026 6103 600082 6385 630005 6358 600027 6104 600083 6397 630006 6357 600028 6105 600084 6413 630007 6063 600029 6107 600085 6496 630008 6035 ~00030 6108 600086 6457 630009 6400 600031 6110 600087 8262 630010 6364 600032 6112 600088 6215 630011 6261 600033 6113 600104 722 630012 6172 600034 6114 600105 6128 630013 6037 6190 630014 6003 600036 6225 630015 6185 600037 6239 610000 6048 630016 6184 600038 6241 610001 6058 630017 6187 600039 6242 610002 6059 630018 6363 600040 6243 610003 6075 600041 6246 610004 6132 600042 6249 610005 6152 640000 6483 ~00043 6415 610006 6460 6484 6416 610007 6463 640001 640002 6461 600045 6417 610008 6465 640003 3287 6!10046 6418 610009 6466 640004 6047 600047 6467 610010 6468 640005 8074 600048 6052 610011 6414 640006 8042 600049 6053 610012 8614 640007 8043 600050 6197 610018 6049 640008 8044 600051 6219 610019 6050 640009 8046 d00052 6220 610020 6119 640010 8047 600053 6237 610021 6121 640011 8080 600054 6259 610022 6131 640012 8081 600055 6420 610023 6446 640013 8082 600056 6479 610024 6447 640014 8083 600057 6098 610025 6459 8098 600058 6064 610026 6122 640015 600059 6173 610027 6452 640016 8107 600060 6174 610028 6073 640017 8121 600061 6175 640018 8189 600062 6176 640019 8190 600063 6178 620000 6223 640020 8191 600063 6179 620001 6382 640021 8192 600065 6181 620002 6407 640022 8193 600066 6186 620003 t491 640023 8194 600067 6195 620004 6492 640024 8195 600068 6196 620005 6501 640025 8198 ~00069 6209 620006 6203 640026 8200 600WO 6210 62GOW 6480 600071 6211 600072 6213 Island Enterprises New No. Old No. New No. Old No. New No. Old No, 640027 8201 650038 6161 710000 7247 640028 8202 650039 6168 710001 7030 640029 8203 650040 6244 710002 7031 640030 8204 650041 6499 710003 7037 640031 8252 650042 1003 710004 7044 640032 8253 710005 7057 640033 8354 710006 7058 640034 8255 660000 6409 710007 7059 640035 8377 660001 6471 710008 7073 640036 8539 660002 6472 710009 7104 640037 3288 660003 6473 710010 7109 640038 6504 660004 6476 710011 7267 640043 8048 660005 6494 710012 7268 640044 6257 660006 6493 660007 6456 660008 649~ 720000 7248 650000 6001 660009 6497 720001 7019 690001 6009 660010 6477 720002 7063 650002 6014 660011 6485 720003 7064 650003 6015 660012 6486 720004 7065 650004 6044 660013 6487 720005 7066 650005 6039 660014 6488 7·20006 7114 650006 6041 660015 6503 720007 7118 650007 6136 660016 6502 720008 7119 650008 6146 660020 8108 720009 7136 650009 6147 660021 8534 720010 7148 650010 6148 660022 6117 720011 7149 650011 6481 660023 6140 720012 7150 650012 6482 660024 6252 720013 7151 650013 6380 660025 6258 720014 7152 650014 6381 660026 6390 720015 7269 650015 6389 660027 6391 720016 7330 650016 6395 660028 6394 720017 7332 650017 6469 660029 6392 720018 7039 650018 6498 660031 6202 720019 7040 650019 6019 660032 6393 720020 7041 650020 6040 6~0033 6255 720021 7125 650021 6042 660034 6247 650022 6045 660035 6166 650023 6074 660036 6250 730000 7067 650024 6159 660037 6167 730001 7071 650025 6160 660038 6163 730002 7072 650026 6254 660039 6054 730003 7139 650027 6272 660040 8235 730004 7262 650028 6356 660041 6248 730005 7270 650029 6373 660042 6164 730006 7271 650030 6375 660043 6253 730007 7341 650031 6377 730008 7263 650032 6060 730009 7264 650033 6061 700000 730010 7265 650034 6222 700001 7256 730011 7266 650035 6474 730012 7115 650036 6475 650037 6162 Island Enterprises New No. Old No. New No. Old No. New No. Old No. 740000 7280 140072 7051 800008 8565 740001 7295 740073 3029 800009 8557 740002 7296 740074 7076 800010 8580 740003 7282 740075 ~7096 800011 8570 740004 7283 740076 7054 800012 8669 740005 7284 740077 8033 800013 8525 740006 7292 740078 7216 800014 8474 740007 7293 740079 7200 800015 8512 740008 7294 740081 7227 800016 8113 740009 7324 800017 8139 740010 7326 800018 8208 740011 7327 750000 7300 800019 8221 740012 7328 750001 7123 800020 8222 740013 7329 750002 7075 800021 8224 740014 7331 750003 7112 800022 8225 740015 7333 750004 7301 800023 8226 740016 7336 750005 7303 800024 8227 740017 7337 750006 7304 800025 8236 740018 7278 750007 7306 800026 8237 740019 7279 750008 7307 800027 8250 740020 7298 750009 7310 800028 6464 740021 7217 750010 7312 800029 8728 740022 7214 750011 7314 800030 8666 740023 7208 750012 7315 800031 8662 740024 7207 750013 7316 800034 8511 740025 7204 750014 7317 800035 8251 740026 7201 750015 7318 800036 8166 740027 7202 750016 7319 800037 8157 740028 7203 _750017 7325 800038 8136 740029 7210 750018 8706 800039 8085 740030 7206 750019 7339 800040 8074 740031 7212 750020 7055 800041 8664 740033 7275 750021 7238 80004·2 8073 740034 7276 750022 7099 800043 8573 740035 7277 750023 7098 740036 7320 750024 7097 740037 7321 750025 7092 810009 8089 740038 7322 750026 7079 740039 7338 750027 7078 740040 7237 750028 7077 820000 8550 740041 7033 750029 7074 820001 8549 740042 7035 750030 7250 820002 8548 740043 7036 750031 7076 820003 8342 740044 7038 820004 8578 740060 7126 800000 8547 820005 8667 740061 7257 800001 8546 820006 8680 740062 7254 800002 8545 820007 8681 740063 7253 800003 8544 820008 8682 740064 7251 800004 8543 820009 8683 740065 7219 800005 8542 820010 8684 740066 7218 800006 8541 820011 8685 740067 7095 800007 8572 820012 8688 740068 7094 740069 7056 740070 7053 740071 7052 Island Enterprises New No. Old No. New No. Old No. New No. Old No. 820013 8652 830016 8749 850007 7313 820014 8582 830017 8750 850008 8369 820015 8563 830018 8751 850009 7122 820016 8514 830019 8752 850010 7016 820017 8515 830020 8714 820018 8517 820019 8660 860000 8228 8210020 8668 840000 8265 820021 8688 840001 7110 820022 8687 840002 8266 820023 8393 840003 8267 911000 2176 2197 820024 8689 840004 8268 911001 820025 8690 840005 8269 911002 2321 820026 8691 840006 8270 911003 3140 820027 8703 840007 8271 911004 4140 820028 8720 840008 8272 911005 4141 820030 8722 840009 8278 911006 4142 820031 8734 840010 8281 911007 4207 820032 8518 840011 8289 911008 5261 820039 8616 840012 8290 912000 2306 820040 8615 840013 8291 912001 3313 820041 8508 840014 8292 912002 3317 820042 8507 840015 8293 912003 6120 820043 8509 840016 8294 912004 28556 820044 8564 840017 8295 912005 ~524 820045 3952 840018 8296 913000 870 82004-6 8210 840019 8297 913001 452 820047 3393 840020 8298 913002 587 820048 6443 840021 8299 913003 592 820049 6444 840022 8355 913004 595 820050 6436 840023 8361 913005 721 820051 6435 840024 8363 913006 722 820052 6065 840025 8364 913007 822 820053 6437 840026 8365 913008 1177 820054 6451 840027 8370 913009 2316 840028 8371 913010 2317 840029 8372 913011 2327 830000 8709 840030 8373 913012 2328 830001 8710 840031 8374 913013 3403 830002 8711 840032 8388 913014 3404 830003 8721 840033 8280 913015 3135 830004 8723 840034 8247 913016 3136 830005 8735 913017 3264 830006 8736 913018 3243 830007 8737 850000 7021 913019 3244 830008 8738 850001 6129 913020 3245 830009 8739 850002 7116 913021 4201 830010 8743 850003 7117 913022 5044 830011 8744 850004 7121 913023 5082 830012 8745 850005 7323 913024 5089 830013 8746 850006 7309 913025 5271 83003~4 8747 913026 7340 830015 8748 Island Enterprises New No. Old No. New No. Old No, New No. Old No. 913027 7034 915003 7101 950013 8655 913028 7025 915004 7132 950014 8609 913029 7020 915005 7135 950015 8676 913030 7220 915006 -7144 950016 913031 7221 915007 7224 950017 913032 7222 915008 7225 950018 8234 913033 7223 915009 7235 950019 8716 913034 7228 915010 7236 950020 2320 913035 7229 915011 7240 950021 7346 913036 7230 915012 7241 950022 7347 913037 7233 915013 7242 950024 8608 913038 7234 915014 7243 950025 8658 913039 7205 915015 7244 950026 8675 913040 7272 915016 7245 950027 8719 913041 7226 915017 7246 950028 8755 913042 8357 915019 5242 950029 8731 913043 8106 915020 5243 950030 8732 913044 8554 915021 5245 950031 8756 913045 8569 915022 5248 950032 8782 913046 8592 915023 5249 950033 8771 913047 8584 915024 5263 950034 8772 913048 585 915025 7018 950035 8773 914000 3983 915026 7281 950036 8774 914001 4143 916000 976 950037 8775 914002 4144 916001 3665 950038 8776 914003 5132 916002 5053 950039 8777 914004 5042 916003 5069 950040 8778 914005 5262 916004 5098 950041 8779 914006 5280 916005 5255 950042 8780 914007 5046 916006 6226 950043 8761 914008 5270 916007 7032 950044 8762 914009 5246 916008 8659 950045 8764 914010 5247 916009 508 950046 8770 914011 5091 917000 5075 950047 8760 914012 5090 917001 986 950048 8763 914013 7006 917002 7124 950049 8769 914014 7239 917003 8538 950050 8768 914015 7249 917004 8571 950051 8767 914016 7022 917007 7105 950052 8766 914017 7215 950053 8765 914018 7311 950054 8742 914019 8027 950055 8754 914020 7042 950056 8759 914021 8021 950000 8698 950057 8781 914022 8022 950001 8700 950058 8783 914023 8023 950002 8702 950066 8218 914024 8026 950003 8707 950067 8567 914025 8165 950004 8708 950075 8238 914026 8182 950005 8656 950076 8661 914027 8183 950006 8557 950077 8540 914028 8378 950007 8693 950078 8533 914029 8733 950008 8692 914·039 8025 950009 8679 915000 7084 950010 8678 915001 7085 950011 8677 915002 7100 950012 8673 Island Enterprises p~" NOTICE OF MISSING INFORMATION Issue\Section TECHNICA~I PUBLICATIOMS LIST Page Number(s) PAC~S The above has been ordered from the source. will reissue As soon as it is received, ATP this fiche to include the above. Island Enterprises